Phenomena Explanations 0.

1 Chatter

The owing chip over the tool face causes frictional force on the tool which is resisted by system stiness and damping This frictional force keeps pushing the tool (or the relative displacement of the tool w.r.t the w/p) in the direction of the compression of system stiness. This motion is accompanied by decreasing of velocity till it becomes ZERO. Until the system stiness gets larger than the frictional force (V=0,X=Max), the system stiness pushes the tool back while increasing velocity and decreasing dierential displacement. while this motion of the tool, velocity is increasing and thereby the frictional forces decreases(due to the theory of the eect of vibrational energy), this means that the resisting force (friction) is decreasing i.e. having negative slope, which is equivalent to a pushing force added to the spring(stiness) force. These forces (with no resistance) causes a very high velocity value at the equilibrium position (V=max, X=0) and continues to have a very high amplitude at the other side, then the system spring (stiness) pushes back again the tool, while also increasing velocity and decreasing frictional force, and thus having added pushing force (due to negative damping force) which leads to a higher velocity amplitude at the equilibrium position (higher than the previous cycle), and this cycle repeats it self every cycle causing an Exponential increase in vibrational amplitude. This exponential increase is due to that the total damping of the system has a negative value. Ths happens only when the negative damping component (decrease of frictional force w.r.t velocity) exceeds the system positive damping (C<0). if the system has a total damping with positive value (C>0) this vibration decays and dies out. And if the system has a total damping with a zero value(C=0) the system has a stable oscillation with the chatter frequency. This phenomoenon can be observed in playing violin or the famous example of a spring -dashpot-mass system on a conveyor with a constant speed that tries to push the mass away from its xation. or it can be observed in aerodynamic utter, braking sqeel, door hing squeel, sound of sliding nger on glass...etc

0.2

How to dierentiate between forced and self excited vibrations experimentally

1. Change rotation speed , if the vibration frequency changes, then this is forced vibrations. 2. Stop displacement (by increasing stiness), if the vibrational force decreases , then this is chatter.

3. Change system parameters, if the vibration frequency is constant, then this is forced vibrations. If the frequency changes then this is self excited vibrations. 4. If forces leads displacement, this is forced vibrations. If forces lags displacement, this is self excited vibrations.

0.3

Eect of Feed on coecient of friction on tool face

the coecient of friction equals to shear stress( over the sliding surface) over normal stress(normal to that surface). While the shear stress is a function of material properties, strain hardening and temperature. The normal stress is a function of the normal load. the cutting forces is directly proportional to the feed (chip thickness) and inversly prop. with the increase shear plane angle(decrease of coecient of friction). so when the cutting forces increase due to feed, the normal stresses increase and thereby (in case of constant shear stress) the coecient of friction decrease,causing again the decrease of cutting forces. thats why the eect of feed on cutting forces is not linear, because theres a closed loop between feed>forces>normal stress>coecient of friction>forces. this also happens when increasing loads on any sliding topological surfaces as in gears, and thats why the eciency of gearboxes increase when increasing loads to a certain limits.