On the Role of Shim Material to Reduce Chatter in CNC Turning

A passive chatter reduction technique with comparing three different shim materials have investigated in present work. CNC Turning operations have carried out with different shim materials of carbide, aluminum, brass and compare it with experimental data of tool without shim. Vibration responses of 36 experiments have acquired with vibration analyzer. Collected data have been processed further with qualitative tool such as TDR, FFT, Poincaré and orbit plot to analysed dynamic motion behavior of single point cutting operation on Al 6063 workpiece. Dynamic motion behavior of cutting tool have provided significant information for production engineers to select optimize cutting parameters to reduce chatter and improve surface roughness of workpiece. ANOVA analysis have been concluded carbide shim is better to brass and aluminum shim material. It is also concluded that cutting tool with carbide shim have less peak to peak displacement amplitude in thrust force direction and hence reduce waviness of surface which led to reduce chatter as well. Quantification of conclusions have been made with by measuring surface roughness and that validated the justification of carbide shim. Softer shim material such as aluminum has not preferable for good surface roughness in CNC turning operation. It is also re validated that cutting speed of 350 m/min is not preferable as it led to make system chaotic.