Reducing Vibration and Chatter in End Mills
When chatter arises it tends to be self-sustaining until the problem is corrected. This condition causes a poor finish on the part and will damage and significantly reduce the life of end mills. Carbide end mills are peculiarly susceptible to damage.
When experiencing chatter problems, the basic reflex action is the reduction of cutting forces. This can be done by:
Even though these steps can and will reduce chatter, slowing down the cutting process is not always the best course of action and reducing the chip load can be detrimental to the cutter.
Better first steps are to improve rigidity and stability:
A common source of chatter is the machining of corners. As the end mills enters the corner the percentage of engagement increases the number of teeth in the cut. This drastically increases the cutting forces, causing chatter. Using circular interpolation and producing a bigger corner radius then the part print calls for then going back and removing the remaining stock with a smaller end mill using circular interpolation will reduce the tendency to chatter.
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