Title: Effect of material inhomogeneity on chatter stability

Authors: Nevzat Bircan Bugdayci; Martin Postel; Konrad Wegener

Addresses: Institute of Machine Tools and Manufacturing (IWF), ETH Zürich, Zürich, Leonhardstrasse 21, CH-8092, Switzerland ' Institute of Machine Tools and Manufacturing (IWF), ETH Zürich, Zürich, Leonhardstrasse 21, CH-8092, Switzerland ' Institute of Machine Tools and Manufacturing (IWF), ETH Zürich, Zürich, Leonhardstrasse 21, CH-8092, Switzerland

Abstract: Chatter vibrations in milling are a widely researched topic in manufacturing science. The models used to predict and mitigate chatter use assumptions for the model inputs. Assuming the workpiece material is homogenous, is such an assumption. In this study, the effect of workpiece material variation on chatter stability is studied. Upon the observation of varying stability limits during milling operations of aluminium blocks, it is shown that the workpiece material inhomogeneity affects the chatter stability. To support this hypothesis, the surface hardness of the workpieces is measured using the Leeb rebound hardness test method. It is shown that the location-dependent chatter stability limits, calculated using the local cutting coefficients, capture the position-dependent stability nature of the experimental data.

Keywords: chatter stability; milling; hardness; material inhomogeneity; stability lobe diagrams; chatter vibrations; stability limits; Vickers hardness; cutting coefficients.

DOI: 10.1504/IJMMS.2022.127209

International Journal of Mechatronics and Manufacturing Systems, 2022 Vol.15 No.4, pp.264 - 285

Received: 14 Mar 2022
Accepted: 23 Jun 2022
Published online: 28 Nov 2022 *