Computational Investigation of Chatter for Face Mill Tool on VMC Using Different Shim Material with Experimental Validation

Abstract

This paper presents the concept, design and development of shim (passive damper) to improve the stability for high spindle speed machine operation of face mill tool. High spindle speed milling machines cause high vibrations and chatter during milling process. Damping and stability of cutting tools is very much essential nowadays in VMC—vertical milling centre operations. The purpose of this study is to understand and improve efficiency of face mill tool by using different types of shim (material). In the research work, we carried out computational analysis (by ANSYS) and experimented with Without shim operation followed by SS—Stainless Steel shim and Carbide shim to observe reduction in chatter. The purpose of this paper is to study static and dynamic operations of face mill tool with different shims (material) which cover analysis of dynamic motion behaviour of face mill tool, behaviour of different types of shim (material) and vibration. SS—Stainless Steel shim has the lowest damping ratio, and SS—Stainless Steel shim has Fc ≤ Fr (chatter frequency is equal to or less than rotational frequency), in all cutting condition. It is concluded that using SS—Stainless Steel shim, we can improve damping capacity of the face mill tool by reducing chatter during vertical milling centre process.