Severe vibrations and chatter noises can sometimes be heard

Severe vibrations and chatter noises can sometimes be heard when one uses milling machine/small end mill cutter to cut c-clamp body piece in your project. Please explain: why that can happen what the contributing factors involved how to prevent it (your recommendations)

Solution

1) The chatter occurs due to the tool vibrations or work piece vibration resulting from the forced vibration induced by the milling machine during its operation.

Tool chatter occurs due to the following factors:

a) Tool deflection,

b) Uncontrolled feed rate.

c) Improper tool position

Work piece chatter occurs due to the following factors,

a) Voids in the workpiece surface,

b) Insufficient reactive forces at the workpiece support surface.

2) The chatter due to work piece is a direct consequent of the tool chatter which exibits a resonant frequency of vibration. The following factors further contribute to the chatter during milling operation,

a) Insufficient lubrication,

b) Inadeqaute removal of chips from the work piece,

c) Improper support walls for the work piece.

3) The primary factor that cause vibration is the tool chatter which then resonates the work piece to produce workpiece chatter. To reduce vibration and increase tool life consider the following practises,

a) Monitor tool deflection at the worksite,

b) Control the feed rate of the tool to avoid shearing failure of the tool,

c) Fill voids in the work piece with a filler material until milling operation.

d) The cutting speed and cutting depth should be proportional,

e) Remove chips from the material and lubricate the tool during operation.