Affordable Ways to Prevent Vibration While the latest machine tool technology may go a long way toward eliminating vibration and chatter, adding a new one may not be realistic. Luckily, there are less disruptive options that can make positive impacts on vibration without breaking the bank. Vibration is a sworn enemy of high-quality, efficient metalworking operations. It hinders speeds and feeds, reduces tool life and makes achieving the fine finishes often required today nearly impossible. There are three typical causes of vibration during machining: 1. Quick changes in direction, stops and starts (either of the table or the cutting tool) cause deflection that impacts the initiating moments of a cut. 2. Inconsistent forces during a cut, such as unbalanced tools or workpieces, as well as the state of engagement of multi-tooth cutters naturally cause some resonance. 3. Because of some instability in the cutting process, chatter, or the buildup of oscillations in the machine tool structure and cutting process, that limit metal removal rates. Machine tool builders are employing high technology in the newest machinery to monitor and manage these challenges. For one, accelerometers can endure the work area’s rough environment while providing accurate and actionable readings.
Other technologies even go as far as gathering data from inside the cut and sending that information to the control, where spindle speed is adjusted when detrimental vibration is imminent. Today’s machine tool construction options also attempt to tackle this age-old challenge, including turcite-lined box ways that resist vibration better than linear guides and machine beds made of cast iron, which is a better damping material than traditional steel. The list goes on and on: shorter, more compact spindles; precision, hybrid bearings; and dynamically balanced spindles. Another one that we work with on a daily basis is a more rigid spindle/tooling interface known as dual contact. Over the past 20 years more than 100 machine tool builders have adopted this configuration, which allows for simultaneous taper and flange contact.
A modular system in both milling and boring setups allows for optimal projections while keeping the damper as close to the cutting edge as possible.
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