International Journal of Machine Tools & Manufacture 61 (2012) 27–47

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International Journal of Machine Tools & Manufacture

journal homepage: www.elsevier.com/locate/ijmactool

A review of chatter vibration research in turning

M. Siddhpura a,b,n, R. Paurobally a,b
a
School of Mechanical & Chemical Engineering, The University of Western Australia, 35, Stirling Highway, Crawley, Western Australia 6009, Australia
b
CRC for Infrastructure and Engineering Asset Management (CIEAM), Brisbane, Queensland, Australia

a r t i c l e i n f o abstract

Article history: Chatter vibrations are present in almost all cutting operations and they are major obstacles in achieving
Received 17 June 2011 desired productivity. Regenerative chatter is the most detrimental to any process as it creates excessive
Received in revised form vibration between the tool and the workpiece, resulting in a poor surface finish, high-pitch noise and
9 May 2012
accelerated tool wear which in turn reduces machine tool life, reliability and safety of the machining
Accepted 10 May 2012
operation. There are various techniques proposed by several researchers to predict and detect chatter
Available online 27 May 2012
where the objective is to avoid chatter occurrence in the cutting process in order to obtain better
Keywords: surface finish of the product, higher productivity and tool life. In this paper, some of the chatter stability
Chatter prediction, chatter detection and chatter control techniques for the turning process are reviewed to
Vibration
summarize the status of current research in this field. The objective of this review work is to compare
Stability
different chatter stability prediction, chatter detection and chatter control techniques to find out most
Turning
Review suitable technique/s and to identify a research scope in this area. One scope of research has been
identified as establishing a theoretical relationship between chatter vibration and tool wear in order to
predict tool wear and tool life in the presence of chatter vibration.
& 2012 Elsevier Ltd. All rights reserved.

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2. Dynamics of orthogonal turning during chatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3. Analytical techniques for chatter stability prediction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1. Stability lobes diagram (SLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.1. Analytical models based on the number of DoF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.2. Analytical models based on compliance/flexibility of tool–workpiece system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1.3. Analytical models considering tool-wear/process damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.2. Nyquist plots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3. Finite element method/analysis (FEM/FEA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4. Experimental techniques for chatter stability prediction and chatter detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1. Signal acquisition and processing techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1.1. Force and vibration measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.1.2. Sound and acoustic emission (AE) measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2. Chip analysis technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3. Artificial intelligence techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3.1. ANN technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3.2. HMM technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3.3. Fuzzy logic technique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5. Chatter suppression/control techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6. Review of chatter and tool wear relationship research . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Appendix A. Publications on different chatter stability prediction techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

n
Corresponding author. Tel.: þ618 64881970; fax: þ 618 64887235.
E-mail address: [email protected] (M. Siddhpura).

0890-6955/$ - see front matter & 2012 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.ijmachtools.2012.05.007
28 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47

Appendix B. Publications on different chatter detection techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Appendix C. Publications on signal acquisition techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Appendix D. Publications featuring artificial intelligence techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Appendix E. Publications featuring chatter control techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1. Introduction friction between tool–workpiece, thermo-mechanical effects or

by mode coupling. Secondary chatter is caused by the regenera-
Chatter vibration has been researched for more than a century tion of wavy surface on the workpiece. Regenerative vibration is
and it is still a major obstacle in achieving automation for most of the most destructive among all other vibrations. Most of the
the machining processes including turning, milling and drilling. research has been carried out to avoid this regenerative chatter
Its catastrophic nature creates numerous problems like poor vibration by either predicting its occurrence earlier or detecting it
surface finish, excessive noise, breakage of machine tool compo- as soon as it occurs. Many researchers tried active or passive
nents, reduced tool life and productivity. Turning is still one of the control strategies to control chatter vibrations, which are also
most widely used machining processes to produce a variety of reviewed in this paper. Quintana and Ciurana [9] recently
products by mostly cutting the metals. The machining of metals is presented a state-of-the-art review of chatter in machining
often accompanied by a violent relative motion between tool and processes and classified current methods which ensure chatter-free
workpiece which is called chatter vibration. (stable) cutting conditions. The process of chatter analysis, chatter
Chatter was first identified as a limitation of machining produc- stability prediction and chatter detection is highly complex which
tivity by Taylor [1], who carried out extensive studies on metal- needs to be investigated independently for different cutting
cutting processes as early as in the 1800s. A 3/4 power law cutting processes like turning, milling and drilling. The literature available
force model was derived and it was stated that chatter is the ‘‘most till date on each of these processes is tremendous and it provides
obscure and delicate of all problems facing the machinist’’. Arnold motivation to the authors of this paper to produce a state-of-the-art
[2] examined numerous influences to which a tool is subjected review focusing on the turning process alone. In this paper, some of
during cutting analytically as well as experimentally for lathes and the chatter stability prediction, chatter detection and chatter control
other machines and explained the mechanisms generating chatter techniques are reviewed exclusively for the turning process and
and proposed cutting forces as a function of speed. It was shown scopes for further research in this field have been indicated.
that the most important characteristic property of chatter vibration
is that it is not induced by external periodic forces, but rather that
the forces which bring it into being and maintain it are generated in 2. Dynamics of orthogonal turning during chatter
the vibratory process (dynamic cutting process) itself. Chatter is
caused by instability in the cutting processes, which was first Machine tool dynamics have been an important issue of
understood by Tobias and Fishwick [3] and Tlusty and Polacek [4] interest amongst the machining community due to its significant
almost simultaneously but independently. It was observed that role in the stability and other outcomes of the processes. The
modulated chip thickness due to vibration affects cutting forces dynamics of the machine tool have great impact on chatter
dynamically, which in turn, increases vibration amplitudes yielding stability of the process. Whatever method is used for predicting
a process known as regenerative chatter. It was also observed that instability, reliable results are only obtained when the dynamics
the depth of cut was the key process parameter in the cutting of the structure and the cutting process are correctly incorporated
process stability. Tlusty and Polacek [4] presented a stability condi- in the method. Earlier chatter research done before 1990 focused
tion in which stability limits can be calculated based upon the mainly on cutting process parameters like speed, feed and depth
system dynamics for orthogonal cutting and analytically showed of cut to be included in the dynamic models of the turning
that for the depth of cuts higher than the stability limit, the process. These models were unable to represent the true nature
magnitude of the dynamic forces and oscillations increases, yielding of machine–tool dynamics and as a result the prediction accuracy
instability and thus chatter vibrations. The solution has been was low. But over the last few decades (After 1990s), other new
approximated by resolving cutting forces and structural dynamics parameters like process damping, tool wear, tool geometry,
into one direction only, i.e., the chip thickness direction and thus can stiffness of machine components, compliance between tool and
only be valid for a one dimensional process. Tobias [5] and Meritt [6] workpiece have been incorporated in the dynamic models of
studied the modeling of the dynamic response, structural aspects machine tool. These new dynamic models are very close to the
and stability limit aspects of regenerative chatter. These studies are real dynamic nature of the machine–tool system and proved to be
only applicable to orthogonal cutting, where the direction of the more accurate in predicting the stability/instability of the turning
cutting force, system dynamics and chip thickness do not change process. These new dynamic models are discussed in subsequent
with time. sections.
In a turning process, three different types of mechanical Regenerative chatter vibration arises due to the interaction
vibrations are present due to a lack of dynamic stiffness/rigidity between the metal cutting process and the machine tool structure
of the machine tool system comprising tool, tool holder, work- as shown in Fig. 1(a) and it is a major obstacle in achieving
piece and machine tool itself as explained by Tobias [7]. These are maximum material removal rate (MRR). Self excited chatter
free, forced and self-excited vibrations. Free vibrations are vibrations are much more detrimental to finished surfaces and
induced by shock and forced vibrations are due to unbalance cutting tools due to their unstable behaviour which results in
effects in machine tool assemblies like gears, bearings, spindles. large relative displacements between the tool and workpiece [10].
Free and forced vibrations can be easily identified and eliminated. Regenerative chatter occurs at the frequency of the most
But self-excited chatter vibrations are still not fully understood dominant mode of the machine tool structure. Excitation of
due to its complex nature. They are most harmful for any this mode causes a relative motion between the machine tool
machining process including turning. and the workpiece due to the tool cutting over a previously
Self-excited vibrations are generally classified into primary machined undulated or wavy surface. Fig. 1(b) displays the
chatter and secondary chatter [8]. Primary chatter is caused by relative motion between the tool and the workpiece in turning.
 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47 29

There are a number of parameters which influence the varying

cutting forces, i.e., effective rake angle, clearance angle and
instantaneous direction of cutting. But in order to determine the
factors which affect most to the dynamic forces, the second
approach to describe the vibratory turning process, in which the
fundamental mechanics of metal cutting are considered and
which is based upon the cutting process model derived by
Meritt [6]. In this second approach, the cutting force variations
are determined by considering the total force at any point during
the cyclic motion of the tool and corresponding to the instanta-
Fig. 1. (a) Machine tool, cutting process interaction. (b) Mechanism of neous values of the cutting parameters and tool geometry. Based
regeneration. on this second approach, a mathematical model has been
formulated below, which represents complete dynamics of the
chatter process and chatter stability prediction of the turning
The tool parameters m, k and c are the mass, stiffness and operation.
damping coefficient, respectively, and V is the cutting velocity of A mathematical model considering a Single Degree of Freedom
the workpiece. Here, x(t) is the wave generated during the current (SDoF) orthogonal turning process with a flexible tool and
revolution and x(t  T) is the wave generated during the previous relatively rigid workpiece is shown in Fig. 2. The model incorpo-
revolution of the workpiece. The phase delay/shift (y) between rates various forces acting on the physical system like the inertia
the waves in the previous revolution x(t T) and in the current force, damping force, spring force and the cutting force. The
revolution x(t) is the key factor governing the occurrence of model is presented by considering a sharp tool with only the
chatter in the turning process. If the two waves are in phase cutting force in feed direction acting in the system.
(y ¼0), the undulations on the workpiece will not grow and the When this SDoF flexible tool is cutting a rigid workpiece, the
process will remain stable because the chip thickness variation is equation of motion of the dynamic system can be modeled in the
negligible resulting in a relatively constant force on the tool. From radial (feed) direction as:
the point of view of energy transfer in the turning system, the € þ cxðtÞ
_ þ kxðtÞ ¼ F f ðtÞ
mxðtÞ ð1Þ
onset of chatter can be regarded as the stability threshold of the
system in which the energy supplied to the system is equal to the where,
energy dissipated by the system. So, when there is no phase
F f ðtÞ ¼ cutting force in feed ðxÞ direction ¼ K f nbn½xðtTÞ2xðtÞ ð2Þ
delay/shift (y ¼0), there is no surplus energy in the system
resulting in a stable cutting process. However, when the waves Kf is the cutting coefficient in feed direction, b is the chip width
are not in phase (y a0), the undulations on the workpiece grow (width of cut), mm, T is the time delay between current time and
due to energy being supplied to the cutting tool and the previous time, [x(t T)  x(t)] is the dynamic chip thickness due to
dissipated energy is less than the supplied energy. This finally tool vibration.
results in an unstable cutting process. Under these vibrations, the Substituting Eq. (2) in Eq. (1) and dividing by m gives
chip thickness varies continuously which in turn creates dynamic
c k Kf b k
cutting forces at a frequency close to one of the natural modes, x€ þ x_ þ x ¼ ½xðtTÞ2xðtÞ ð3Þ
and further excites the system. m m k m
Chatter can be recognized by the noise associated with these Applying Laplace transform and using relations,
vibrations, by the chatter marks on the cut surface, and by the
k c Kf b
appearance of the chips produced in turning. Machining with o2n ¼ , ¼ 2zon and assuming j¼
m m k
chatter is mostly unacceptable because of the chatter marks on
the machined surface and because the large peak values of the s2 þ2zon s þ o2n ¼ jo2n ðesT 1Þ ð4Þ
variable cutting force might cause breakage of the tool or of some From Eq. (4), the transfer function of the system with a sharp
other part of the machine [11]. Chatter is often a factor limiting tool can be obtained by direct derivation from differential
metal removal rate below the machine’s capacity and hence equation as [20],
reduces the productivity of the machine.
It would be a challenging task to identify/measure dynamic 1
GðsÞ ¼ ð5Þ
parameters of the dynamic chatter model. There are basically two s2 þ2zon s þ o2n
approaches to formulate analytic expressions describing the
Substituting s ¼jo into Eq. (5), where o is the chatter vibration
turning process dynamics [12]. The first has been to specify
frequency, the real and imaginary parts of the transfer function
incremental cutting force equations of suitable form, and to
are found as,
derive the values of the coefficients of these expressions
from steady-state cutting tests [3,13,14] or by fitting to experi- o2n o2
GðoÞ ¼ ðReal partÞ
mentally derived stability charts [15,16] or by fitting the expres- RðoÞ
sions to the results of dynamic/vibratory cutting tests [17,18].
It is clearly much more straightforward to use steady-state tests,
if a wide range of cutting conditions have to be investigated. A
unified mathematical model was presented by Kaymakci et al.
[19] which can predict cutting forces for turning, boring, drilling
and milling. This generalized model incorporates tool/cutter
geometries of these multiple cutting processes according to ISO
standards and predicts cutting forces considering oblique
mechanics. The model seems quite promising because it can even
be used to develop unified chatter stability laws for multiple
operations. Fig. 2. SDoF orthogonal turning model.
30 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47

ð2zon Þo
HðoÞ ¼ ðImaginary partÞ ð6Þ
RðoÞ
where,
RðoÞ ¼ ðo2n o2 Þ2 þð2zon Þ2 o2 ðDenominatorÞ
on is the natural frequency of the system, o is the frequency of
chatter vibration.
The limiting width of cut at which the turning process
switches from stable to unstable can be found by the relation
[21]:
1
blim ¼  ð7Þ
2K f GðoÞ

The stability equation leads to a positive real depth of cut only

when the real part G(o) of the transfer function between the tool
and workpiece is negative. So, Eq. (7) gives only an absolute depth
of cut when the minimum (most negative) value of G(o) is
considered.
Defining the phase angle Fig. 3. Typical SLD showing the stability lobes/regions for various speeds and
widths-of-cut.
HðjoÞ
c ¼ tan1
GðjoÞ
and with some mathematical manipulation, the spindle period (T) construction of SLD, Nyquist plots and finite element method/
and phase shift (y) can be obtained as, analysis are most frequently utilized techniques in the literature
are reviewed critically here. Fig. 4 shows the number of publica-
1 
T¼ 2np þ y , y ¼ 3p þ 2c ð8Þ tions for each technique. It should be noted that multiple citing is
o possible as some publications may repeat in each category in
The spindle speed can be obtained by: Figs. 4, 6–9. The construction of SLD is the most popular
N ¼ 60=T ð9Þ technique among researchers because of its simplicity and clarity
in defining stable and unstable cutting states. The SLD can be
Eqs. (7)–(9) can be used to produce the so-called stability lobes produced for mathematical models containing any number of DoF
diagram (SLD) showing the relationship between the limiting (degrees of freedom) cutting processes.
width of cut (blim) and spindle speed (N) for the turning operation
as shown in Fig. 3. The chatter SLDs are constructed by scanning 3.1. Stability lobes diagram (SLD)
the possible chatter frequencies from the transfer function where
the real part is negative, e.g., G(o)o0. The SLD distinguishes The most significant cutting parameter, which is decisive for
regions of stable (chatter-free) and unstable cutting operation for the generation of chatter in a turning process, is the depth of cut
different combinations of width of cut and spindle speed. When (chip width) b. The cutting process is more stable when the chip
the width of cut and spindle speed are selected under the stability width is smaller. By increasing chip width, chatter starts to occur
lobes, the process would be stable leading to a smooth surface at a certain chip-width blim (limiting depth of cut) and becomes
finish and less dynamic loads on the machine tool system [21]. By more energetic for all values of b4blim. Therefore, blim is the most
selecting specific combinations of width of cut and spindle speed, important parameter for the stability of cutting. The value of blim
chatter vibrations can be avoided to achieve a stable turning depends on the dynamic characteristics of the structure, on the
process throughout. workpiece material, cutting speed and feed, and on the geometry
To obtain the dynamic parameters numerically, finite element of the tool [29]. SLD can be used for the prediction of chatter
method technique can be used which is discussed in Section 3.3. stability in a turning process. The limiting depth of cut blim is
Impact testing is the most conventional experimental method for plotted against spindle speed (N) on the SLD as shown in a typical
obtaining dynamic parameters for the chatter model. In particu- plot similar to Fig. 3. Vibrations between the tool and workpiece
lar, the natural frequency, damping ratio, Real and Imaginary appear as different lobes (n ¼1, 2, 3, y) and any depth of cut and
parts of the transfer function are determined by impact testing spindle speed combination which falls below these lobes results
technique which has been used by several researchers [10,22–28]. in a stable (chatter-free) operation and above these lobes in an
The structural stiffness (k) of the tool–workpiece system can be unstable (chatter) operation. With the help of SLDs it is very easy
obtained by simultaneous measurement of displacement and to choose ideal spindle speed and depth of cut combinations for
static force applied at the end of the workpiece through the tool maximum MRR in a turning process.
as shown in [10,24,28]. Meritt [6] presented stability conditions through stability
Machine tool dynamics is a wide field of research and thus charts, in which it was possible to predict chatter in terms of
reviewing only the dynamics of the machine tool can become a process parameters, such as depth of cut and spindle speed. This
new research work itself. Only a few papers describing the effect was an important contribution since it allowed an improvement
of machine tool dynamics on chatter have been discussed in this in material removal rate without chatter by selecting appropriate
work as this work mainly focuses on the chatter vibrations in a process parameters. Linear chatter stability models presented by
turning process. Das and Tobias [13] and Tlusty [30] have considered the effects of
instantaneous, regenerative chip thickness on the dynamic force.
3. Analytical techniques for chatter stability prediction The stability models presented here did not include the complete
chip formation process. However, the CIRP group formed and led
Various techniques are available in the literature for the by Tlusty found that the chatter in turning and other operations
analytical prediction of chatter stability conditions. Among them, does not result from the negative damping of the chip formation
 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47 31

process but from self-excited vibrations due to force– needed since the SDoF stability formulation fails to represent the
displacement interaction between the machine tool and the dynamics of the process accurately. Dassanayake [37] studied tool
cutting process. To generate SLDs, analytical modeling can be chatter with turning dynamics using a 3DoF model and also
done by considering different parameters in the model, which are compared it with an SDoF model. In a 3DoF model the workpiece
reviewed in the following subsections. is modeled as a system of three rotors namely, machined, being
machined, and unmachined regions connected by a flexible shaft.
It was found that neglecting workpiece vibrations in modeling
3.1.1. Analytical models based on the number of DoF fine turning operation would misinterpret machining dynamics
A turning process can be modeled by considering an SDoF and inevitably impact the surface finish and geometrical tolerance
orthogonal process, 2DoF or 3DoF systems. To obtain critical of the final product. It means that the workpiece vibrations
chatter free cutting parameters, analytical prediction of chatter should also be considered along with tool vibrations for more
stability limits for orthogonal cutting is necessary which is well accurate modeling of the turning process.
documented by Tobias and Fishwick [3], Merritt [6], Tobias [7], Suzuki et al. [38] presented an SDoF and a 2DoF analytical
Tlusty [31] and Altintas and Weck [32]. In most of these research model by defining equivalent transfer function to understand the
works, the turning tool is represented by an SDoF spring–mass effects of the cross transfer function and the cutting force ratio on
system which is cutting a rigid workpiece where the cutting force chatter stability. It was found that critical widths of cut in the CW
is linear with the process parameters. The research carried out (clockwise) and CCW (counter clockwise) rotation processes were
with such assumptions is referred to as linear stability analysis/ significantly different from each other in the experiment, even
theory. Cutting tool parameters like tool angles and wear have when the other conditions were the same. Both analytical models
been accounted for in the models to understand their effects on based on SDoF and 2DoF systems give the same solutions. SDoF
chatter stability. Hanna and Tobias [33] presented an SDoF time system analysis gives the solutions easily and clarifies the effects
delay-differential equation with square and cubic polynomial of the cross transfer function and the cutting force ratio on chatter
terms; these nonlinear terms were related to structural stiffness stability. Stability limits have been estimated from the vector
and cutting force. The model has predicted the chatter stability, diagram of the equivalent transfer function. It was also found that
which is affected by the width of cut in three ranges like an the 2DoF model is redundant and not useful in understanding the
unconditionally stable range, a conditionally stable range and an plunge cutting process.
unstable range. But it is quite clear from the work that even if the Dombovari et al. [39] presented an SDoF model of orthogonal
cutting process is considered stable, there is an existence of cutting to analyze large-amplitude motions. The model was
unstable periodic motions, which limits the application of linear formulated as a delay differential algebraic equation (DDAE) and
stability theory for manufacturing industries. included the regenerative effect of the turning process and the
Chandiramani and Pothala [34] depicted the dynamics of nonsmoothness when contact between the cutting tool and the
chatter with a 2DoF model of the cutting tool which is quite workpiece is lost. The simple SDoF model has been employed to
oversimplified. It was found that an increase in the width of cut derive a smoothed version of the orthogonal cutting system
causes frequent tool-leaving-cut events and increased chatter without algebraic effects and it displays complex dynamics
amplitudes. The frequency of tool disengagement was increased including chaotic oscillation in the process. After reviewing these
with cutting velocity, despite the cutting force in the shank analytical models based on the number of DoF, the authors
direction remaining constant over a certain velocity range. The
chatter amplitude increases and then decreases when the cutting
velocity or the uncut chip thickness is increased. Since chatter
vibration is between the tool and workpiece, models for both are
considered generally. The shooting technique used to calculate
periodic solutions is not efficient enough and some structural
nonlinearities should have been included in the model to make it
more accurate too. Budak and Ozlu [35,36] compared an SDoF and
multi-dimensional stability models by several simulations and
chatter experiments. The effects of three cutting angles, the insert
nose radius and the dynamics of the components were included
in the cutting system in all directions in their 3DoF model. As
these parameters cannot be included in an SDoF model, it can give
erroneous results. It was also shown that when inclination angle
or nose radius exists on the tool, a multi-dimensional solution is Fig. 5. (a) Flank-wear on a turning tool. (b) Flank-wear profile.

Years SLD Nyquist FEM Total

1960- 2 1 0 3
1970
1971- 2 0 0 2
1980
1981- 0 1 0 1
1990
1991- 3 1 0 4
2000
2001- 22 5 6 33
2012
TOTAL 29 8 6 43

Fig. 4. Number of publications featuring analytical chatter stability prediction techniques and the table showing summary of the selected publications between years 1965
and 2012. (Please refer to Appendix A.)
32 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47

Signal Chip Artificial

Years Total
processing analysis Intelligence
1941- 1 0 0 1
1950
1951- 0 0 0 0
1960
1961- 2 0 0 2
1970
1971- 3 0 1 4
1980
1981- 8 1 0 9
1990
1991- 16 0 4 20
2000
2001- 34 5 5 44
2012
TOTAL 64 6 10 80

Fig. 6. Number of publications featuring experimental chatter detection techniques and the table showing summary of the selected publications between 1946 and 2012.
(Please refer to Appendix B.)

Years Force Vibration Acoustic Total

1941-
1 1 0 2
1950
1951- 0 0 0 0
1960
1961- 2 0 0 2
1970
1971- 2 2 1 5
1980
1981- 5 3 5 13
1990
1991- 14 13 2 29
2000
2001- 21 25 9 55
2012
TOTAL 45 44 17 106

Fig. 7. Number of publications featuring signal acquisition techniques and the table showing summary of the selected publications between 1946 and 2012. (Please refer
to Appendix C.)

Years ANN HMM FUZZY Total

1971-1980 0 0 1 1
1981-1990 0 0 0 0
1991-2000 3 0 1 4
2001-2012 4 1 1 6
TOTAL 7 1 3 11

Fig. 8. Number of publications featuring Artificial intelligence techniques and the table showing summary of the selected publications between 1978 and 2012. (Please
refer to Appendix D.)

Years Passive Active Total

1961-1970 1 0 1
1971-1980 0 1 1
1981-1990 2 0 2
1991-2000 2 10 12
2001-2012 4 11 15
TOTAL 9 22 31

Fig. 9. Number of publications featuring chatter control techniques and the table showing summary of the selected publications between 1965 and 2012. (Please refer to
Appendix E.)

observe that there is no point of creating a model with two or However, it would be a challenge to create a more realistic multi-
higher degree of freedom if it does not provide much better dimensional chatter model of the process by incorporating all the
prediction than the SDoF model. Even a simple SDoF model provides geometrical and dynamic parameters along with the nonlinear
quite accurate prediction of chatter stability for the turning process. relationships associated among these parameters.
 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47 33

3.1.2. Analytical models based on compliance/flexibility of tool– input parameters of the model like cutting coefficients and modal
workpiece system parameters. There are very few research works which considered
Only a few researchers have considered tool and workpiece compliance of tool–workpiece system and the authors believe
flexibilities in the analysis of chatter vibration and chatter that the tool–workpiece compliance should always be considered
stability prediction. Shanker [40] proposed a general method for to constitute a more realistic model.
the analytical evaluation of the stability limit in oblique turning of
a slender workpiece, held between the centers. The method
considered the effects of the workpiece dimensions and its 3.1.3. Analytical models considering tool-wear/process damping
compliance. The compliance of the head and tailstock centers, Tool wear phenomena occur during a cutting process and it
system damping and other important cutting parameters were changes the tool geometry resulting in a drastic change in the
also considered to predict the chatter stability accurately. dynamics of the cutting process. Several types of wear occur
Benardos et al. [41] considered a rigid tool and a flexible work- during the cutting process. The most important types are crater
piece for analytical modeling of a turning process. The flexible wear (CW), flank wear (FW) and notch wear (NW) as described by
workpiece which is supported only at one end undergoes elastic Tlusty [31]. Flank wear has been emphasized more than crater
deformation reducing allowable depth of cut in the process. The wear during analysis of cutting tool wear. Thangavel [46] stated
results also show the impact of not having a tailstock on that flank wear results in changes to the mechanics of the cutting
cylindricity of the workpieces due to the effects of numerous process and changes in the dimension of the product. But it was
forces generated by the cutting tool. Although there is a qualita- also stated that flank wear increases the tendency for chatter
tive agreement between analytical and experimental results which is quite contradictory and seems incorrect. The single most
which supports the cutting mechanism of the work, the quanti- significant type of wear that has drawn constant attention is
tative performance in terms of measured deflections of the flank wear, which is generally used as a tool life criterion.
workpiece was not satisfactory due to the fact that the boundary Fig. 5(a) illustrates the location of flank wear on a turning tool
conditions of the analytical model assumed zero elastic deflection and Fig. 5(b) shows detailed flank wear profile where VB is the
of the workpiece which is not true in reality. average flank wear width, VBmax is maximum peak land width
Chen and Tsao [42,43] presented 2DoF dynamic models of a and lw is flank wear length/flat. The tool life criterion is generally
cutting tool with and without the tailstock supported workpiece taken as VBr0.3 mm and VBmax r0.6 mm. The flank wear length
using beam theory. The effects of workpiece parameters are (lw) is very critical in positive damping in the occurrence of
studied on the dynamic stability of the turning process by treating chatter vibrations as explained by Tlusty [31].
the workpiece as a continuous system. The effect of the critical Sisson and Kegg [47] found that high stability at low speed is
chip width under different spindle speed was investigated. By caused by the damping generated at the tool–workpiece interface
considering the deformation of the workpiece under different and reported that the finite radius of the tool nose, clearance
conditions, the results showed that the critical chip width of the angle and cutting speed are the most important factors affecting
deformed case was always larger than the rigid body case the process damping and which cause deviation of experimental
especially at lower natural frequencies. Although these 2DoF results from the predicted results. The preparation of the tool
models are very good at predicting the stability and evaluating cutting edge can have a dramatic influence on the damping
the influence of the elastic deformation and the workpiece natural produced by the cutting process. Thus, changes in the edge radius
frequency on the critical chip width for two different workpiece of the cutting tool may produce the desired effect on the cutting
end conditions, they are very complex for studying the three- process. It was also recognized that the process damping caused
dimensional model and nonstationary cutting conditions, parti- due to the interference between the cutting tool flank face and the
cularly in the case of the vibratory situations. undulated machined surface. Wu [48] presented a model of
Vela-Martı́nez et al. [44] developed a multiple degrees of tool–workpiece interaction where the tool is indenting the work-
freedom model based on the compliance between the cutting piece surface and generates undulations on it. The ploughing
tool and the workpiece, which was compared with an SDoF force which is acting on the flank face of the tool is assumed to
model. This compliant model predicts a larger stability area when be proportional to the volume of the material extruded on
compared with the SDoF model, but this result is not yet the workpiece. Elbestawi et al. [49] and Lee et al. [50] showed
experimentally validated. This model can be used to predict that the ploughing force acts like an additional damper in the
stability limits more accurately when the dynamics of both the system after applying the ploughing force model in numerical
cutting tool and the workpiece are similar or when slender simulations.
cutting tools must be used. Ahmadi and Ismail [51,52] proposed that the numerical
Sekar et al. [24] considered the effects of deflections of a calculations of the extruded volume requires high resolution in
tailstock-supported workpiece and presented a compliant 2DoF descretizing the surface undulations, which makes establishing
dynamic cutting force model by considering the relative motion the SLD a time consuming task. It was stated that the indentation
of the workpiece with the cutting tool. It was found that when a model is nonlinear since the extruded volume is computed only
slender and flexible workpiece is being cut, the critical chip width for the part of the vibratory cycle when the tool is moving into the
at higher speeds is considerably larger than a rigid workpiece. The workpiece and it is zero when the tool is moving away from the
effect of cutting position, workpiece dimensions, cutter flexibility workpiece. It is nonlinear because it depends on the surface
and cutter damping on the dynamic stability is very well undulations amplitude. Due to these facts, it is still not possible
presented in this dynamic model. Urbikain et al. [45] presented to implement this model directly in analytical modeling to predict
an algorithm to predict stability in straight turning of a flexible the stability of the cut.
workpiece by Chebyshev collocation method. This SDoF compli- Chiou et al. [28,53] approximated this indentation model with
ant model incorporates variables like round inserts, tool lead a linear model with first order Fourier transform. A small
angle, cutting speed and depth of cut. The finite element (FE) amplitude vibration was assumed in this model. The stability
model of concentrated mass workpiece was analyzed using lobes were generated by integrating the approximate linear
ANSYS to find dynamic parameters. The compliant model is useful model into their analytical development. It was demonstrated
for low order lobes and provides accuracy in stability prediction that chatter instability is delayed to a greater overhang distance
for up to 87.5% but inaccuracies arises from modeling and the as a result of flank wear. And at lower cutting speeds, the chatter
34 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47

limit increases as the tool wear increases. The effect of tool wear process when it is critically stable during cutting tests. Stability
on the chatter stability was investigated and it was found that the lobes were constructed using this identified process damping
chatter stability increases as the tool-wear-flat enlarges. coefficient. It was found that once tool wear reaches a level that
Clancy and Shin [54] presented a three-dimensional frequency covers the vibration wave left on the surface, process damping
domain chatter stability prediction model for face turning by becomes fully effective and additional tool wear does not
including tool wear in the model. This model could predict the significantly change the damping during the process. Very
magnitude and direction of the process damping force, which was recently, Tunc- and Budak [60] have extensively explored the
also used to analytically calculate stability limits. The results process damping phenomena with some additional insights by
showed that the flank wear and the stability limit were directly focusing on the effect of cutting conditions and tool geometry on
proportional to each other. As wear developed on the flank of the process damping and stability analytically as well as experimen-
tool the stability limit was increased due to process damping tally. Cylindrical flank face geometry was suggested over planar
effect. This means that the larger the flank wear area becomes, the flank geometry to achieve higher process damping and stability.
higher the stability limit will be. It was also found that the process Higher vibration frequency and amplitude increased indentation
damping has a larger effect at lower spindle speeds resulting in volume on the flank face resulting in a higher process damping
very high stability for worn tool in compare to fresh tool. And at a and thus stability. This clearly indicates that the process damping
very high speed this effect is negligible resulting in lower stability phenomena is still being exploited and has potential to achieve
limits. higher process stability through modeling it more precisely.
Fofana et al. [55] investigated stability of a turning process Process damping is a very important phenomenon which
analytically as well as experimentally by using worn tool inserts. occurs at low speed but it is very crucial to consider it at the
Cutting forces were investigated with varying depth of cut and modeling stage as it significantly affects the stability limit pre-
feed rate, whereas cutting force coefficients were investigated as dictions. Identification of process damping coefficient either
the tool wear progresses. It was shown that tool wear and analytically or by dynamic testing is also quite essential.
dynamic instability are both due to the combined effect of the After reviewing different analytical models/techniques it was
contact and friction mechanisms between tool–workpiece, tool– observed that an analytically obtained SLD usually changes with
chip and workpiece–tool–machine–tool interactions. the machine tool, work material and tool geometry. So it is
Altintas et al. [56] presented a linear model, and verified that difficult to apply such SLD in practice since the SLD is different
the damping coefficient is approximately proportional to the ratio case by case. Moreover, any analytical technique used in obtain-
of vibration and cutting speeds. Controlled oscillation tests were ing the SLD cannot describe high stability property at lower
carried out using a fast tool servo to identify the proportionality spindle speed due to the use of a static model of the cutting
constant of the process damping. The stability charts were (turning) process.
obtained using the Nyquist criterion considering the process
damping. It was found that accurate prediction of chatter stability 3.2. Nyquist plots
at low speeds is dependent on the identification of the dynamic
cutting force coefficients. The coefficients were found to be Some researchers used control theory to predict chatter
sensitive to the work material properties, cutting edge prepara- vibrations. It includes the use of Nyquist plots. Nigm [61]
tion, tool clearance angle, tool wear, cutting speed, tool– proposed a method based on the feedback control theory which
workpiece contact mechanics, shearing process, wavelength and was conceptually similar to that of Merritt [6], but it has the
the frequency of vibration during machining. advantage of accounting for the dynamics of the cutting process.
Moradi et al. [57] presented an SDoF model of a turning The analysis method was strong enough for implementing it
process. In this model, an orthogonal cutting configuration is either graphically or analytically and it could account for the full
used to set up the nonlinear delay differential equation of motion range of regeneration. The author used Nyquist criterion to
that includes the effects of tool flank wear. Modeling and stability predict the stability. The method only requires plotting the
analysis were carried out by considering sharp tool and worn tool operative receptance instead of plotting the open-loop frequency
where tool flank wear was modeled as the contact force. It was response locus as required by the Nyquist criterion. Plotting the
shown that the introduction of tool wear to the model adds operative receptance is even less time consuming than plotting
damping to the system and creates a speed-dependent variation the open-loop frequency response locus. Minis et al. [62] used the
in the critical width of cut, showing higher stability limits at Nyquist criterion as an alternative approach to derive the critical
lower speeds. Tool wear length was the parameter representing stability parameter by finding the left-most intersection of the
tool wear in the model. It was also found that the critical value of Nyquist plot with the negative real axis. But this approach could
width of cut increases by a parabolic trend when the tool wear be applied to only two-dimensional orthogonal machining. Wang
length is increased. and Cleghorn [63] also performed stability analysis using the
Budak and Tunc [58] determined the indentation force coeffi- Nyquist criterion. The chatter stability of the dynamic cutting
cient responsible for the process damping through energy analy- process is solved using the Nyquist criterion by Altintas et al. [56]
sis. This coefficient is identified from the chatter test and it is used to identify the dynamic cutting force coefficients for analyzing the
for process damping and the stability limit predictions. It was effect of cutting speed, tool wear, vibration frequency and
demonstrated that decreasing clearance angle increases the wavelength on the chatter stability. It was proposed that the
process damping which is a well-known effect in practice. The amount of removed material is dependent on the uncut chip area.
process damping was only observed at very low speeds with Eynian and Altintas [64] presented an SDoF and 3DoF turning
sharp tools, it exists at relatively higher cutting speeds for honed model for stability prediction by modeling the transfer matrix
tools. Process damping was found to be the significant source for between the displacements and cutting forces. The process
increased stability at low speeds in an orthogonal turning process damping force is also included in the model and finally stability
which was verified by time domain simulations and experiments. prediction is analytically carried out using the Nyquist criterion.
Kurata et al. [59] have also identified the process damping Turkes et al. [25] predicted chatter vibrations in orthogonal
force coefficient from the plunge turning tests. The process cutting with an SDoF turning system by modeling the process
damping coefficient is estimated by inverse solution of the according to OTF (oriented transfer function) and t decomposition
stability law using the characteristic equation of the turning forms. The stability of the system by applying OTF and t
 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47 35

decomposition form to the Nyquist criteria was also investigated. onset in online mode. These experimental techniques have
Analytical technique (Nyquist technique) was compared with the potential to establish an unmanned machining environment.
TDS (time domain simulation) technique. Some experimental techniques are employed offline for the
The problem with the Nyquist technique is that it can only be chatter stability prediction by producing the SLD of the system
applied to determine if the cutting conditions are stable. So the with the help of modal parameters of the tool–workpiece
TDS technique is clearly superior to the Nyquist technique system obtained through modal testing. However, this SLD would
because it provides stable and unstable regions on SLDs by be a semi-analytical one. A true/realistic SLD would rather be
comparing width of cut and cutting speed. The TDS technique obtained with the help of actual cutting tests, however the
involves some outstanding aspects such as nonlinear character- task involved in obtaining SLD by direct cutting test is very
istics of the cutting operation and it is a more effective technique tedious and time consuming. The experimental validation/verifi-
for analysis. cation is imperative to know whether a specific process is stable
based on the comparisons with the theoretical chatter onset
3.3. Finite element method/analysis (FEM/FEA) conditions obtained from the chatter stability prediction model
and by identifying chatter onset in the cutting process. This
There are different other techniques presented in the literature identification is possible using tool condition monitoring (TCM)
for the development of analytical stability analysis. One of them is techniques.
FEM/FEA. Wang and Cleghorn [63] presented a finite-element Experimental techniques are classified and reviewed here
beam model of a spinning stepped shaft workpiece to perform based on techniques used for chatter stability prediction and
stability analysis using the Nyquist criterion. Baker and Rouch chatter verification (detection). Fig. 6 provides information about
[65] analyzed the instability of a machining process using the the number of publications for the most frequently used experi-
FEM technique and created a structural model of the machine tool mental techniques like signal processing, chip analysis and
system using the commercial ANSYS software but the integrity of artificial intelligence methods.
the results is not validated by experimental results. The effect of The condition monitoring system for any machine tool is
structural parameters was investigated on machine instability necessarily custom built and thus depends upon the type of the
without assessing the dynamics of the cutting process models. machine tool as described by Siddhpura et al. [68]. Tool condition
However the method presented allows for inclusion of both monitoring can be carried out using force, vibration and acoustic
cutting tool and workpiece flexibility in the analysis. Mahdavine- signals which are very useful for the monitoring of the process.
jad [66] predicted the stability of a turning operation by finite Armarego et al. [69,70] repeated orthogonal cutting tests for a
element analysis using ANSYS software. The flexibility of the range of cutting speed, rake angle and uncut chip thickness to
machine’s structure, workpiece and tool has been considered in generate an orthogonal cutting database for a certain tool and
this FEA model. Brecher et al. [67] proposed a FEA-based work material pair. Knight [71] presented experimental stability
3-dimensional turning model. This 3D-FEA model has the poten- charts for turning with a simplified machine–tool structure model
tial to determine the resulting cutting forces for even complex- for various cutting conditions and these show considerable
shaped tool geometries. An approach was used to reduce variations in the level of stability with speed, feed and rake angle.
the calculation time by using characteristic diagrams for the
calculated process forces in the FEA-model by focusing on the 4.1. Signal acquisition and processing techniques
thrust and feed forces. FEM/FEA technique is quite useful in
predicting the stability at the design stage of any process, which Verification and detection of predicted chatter stability is
saves heaps of time and money in any production environment. possible with various sensors which can measure force, displace-
Urbikain et al. [45] performed a FE model in ANSYS using 3D ment, velocity, acceleration, acoustic signals generated from a
10-node tetrahedral solid elements type SOLID92 for the work- machining process. Various sensors are used to acquire the above
piece. Different geometries were designed and analyzed giving as signals and become part of the signal acquisition system. Fig. 7
a result a final workpiece of 35,516 elements. Afterwards a FE provides information about the number of publications for each of
analysis was carried out to produce a workpiece and the modal these signal acquisition techniques. Signal processing is then
parameters were periodically updated to consider workpiece carried out to obtain useful information from the signals received
evolution during machining within the stability algorithm. through the sensors. Traditional signal processing techniques like
A limitation with any FEM model is that it cannot take into time-domain, frequency domain and time–frequency domain
account the properties of the joint between the mating parts of analysis are generally explored.
the machine tool as these properties are difficult to describe Tlusty and Andrews [72] reviewed several sensors and their
mathematically. With the advancements in computing capabil- capabilities for chatter detection, tool breakage detection in
ities and technology, the futuristic analytical models are more machining processes in order to develop an unmanned machining
likely to be studied using FEM/FEA techniques. centre. Force, vibration and acoustic sensors were tested for
turning and milling. It was found that the force signals were the
best signals for chatter detection in comparison to vibration
4. Experimental techniques for chatter stability prediction signals. Because chatter is a relative vibration between the tool
and chatter detection and the workpiece and, as such, is difficult to measure with a
vibration transducer whereas the cutting force is a direct indi-
Due to increasing demand of cutting down the production cator of the relative vibration between tool and workpiece and
costs under market pressure, unattended machining is the key very characteristic patterns of force variation make it possible to
feature in most of the manufacturing industries. So, in unmanned clearly distinguish chatter.
turning operation, automatic detection of regenerative chatter Heyns [73] reviewed these signal processing techniques and
is very important in order to avoid detrimental effects on surface found that the time domain and frequency domain methods are
integrity and damage to the workpiece or machine tools caused used extensively for tool wear and chatter estimation. But time–
by catastrophic tool failure resulting from large amplitude frequency domain methods like Wavelet transform have higher
vibrations. Experimental techniques are useful in predicting capabilities which have not yet been completely exploited.
the stability condition in offline mode and detecting chatter Zhu et al. [74] argued that time domain methods are most
36 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47

commonly used in TCM, but these methods lose some signal Thomas and Beauchamp [26] carried out statistical investiga-
information in the time domain. Fast Fourier Transform (FFT) and tion of modal parameters of cutting tools in dry turning. Cutting
Wavelet Transform (WT) were compared and it was found that forces were measured using strain gauges in the tangential and
WT is far more effective than FFT, because of its scarcity and radial directions. A tri-axial accelerometer was mounted on the
localization properties. WT yields frequency information in a tool to measure accelerations in the feed, cutting or tangential
time-localized fashion. WT has great potential in detecting abrupt directions, and also in the thrust or radial directions. Acceleration
changes in tool conditions in TCM. It is robust and insensitive to signals were analyzed in the frequency domain using an FFT
changing working conditions. Analyzer. It was also found that increasing the tool nose radius
reduces the tangential cutting force. This allows a larger feed rate
to be used which decreases the machining time and hence
4.1.1. Force and vibration measurements reduces the unit production cost.
Force and vibration signals are preferred by most of the Chiou et al. [53] experimentally validated an analytical
researchers because they provide thorough insight into the stability model including process damping. The characteristic
dynamics of the cutting process and they are very useful in parameters like cutting stiffness, structural stiffness and
the condition monitoring of machining processes. The force and natural frequency, damping ratio and specific contact force
vibration measurement technique is one of the most commonly were determined experimentally. For this, a dynamometer
used techniques in detecting regenerative chatter, due to the was mounted to the tool post to measure cutting forces in the
complex relationship between cutting forces, vibrations and feed and cutting directions. The impact testing was carried out
mechanisms causing chatter. Different signal processing techni- to identify the structural response of the machine–tool system.
ques are used to obtain the required signals from force and The displacement of the tool and velocity ratios were obtained
vibration measurements. from acceleration signals detected from a pair of acceler-
Shanker [40] verified his 2DoF chatter stability prediction ometers mounted to the tail stock, one horizontally and the
model with a flexible workpiece for oblique turning by impact other vertically, during machining at different surface veloci-
testing and vibration measurements. The natural frequency and ties. It was demonstrated that the effect of tool wear flat is to
the system damping of the workpiece were determined by enlarge the range of stable cutting while the effect of the
exciting it at several points along their length and obtaining a Coriolis force associated with the spinning of the workpiece is
resonance curve. The chatter frequency was recorded by a vibra- the reverse, especially at high cutting speeds, through their
tion pick-up mounted on the tool shank. It was proposed that tool effects on the system damping.
geometry has little effect on the limit of stability, but the stability Chiou and Liang [28] measured the vibration of the turning
is significantly affected by dimensions and compliance of the tool by an accelerometer attached to the back of the shank. The
workpiece. acceleration signals were amplified by a charge-amplifier prior to
Rahman and Ito [75] presented a method to determine the being digitized with an emulated digital oscilloscope. The accel-
onset of chatter by online measurement of the horizontal deflec- eration signals were used to observe the sudden change of the
tion of the workpiece using eddy current type displacement pick- vibration amplitude to detect chatter conditions. Impact testing
ups. A piezoelectric type three-component dynamometer was was carried out to identify natural frequency and damping ratio
also used for in-process measurement of cutting forces. This associated with the cutting tool. Forces were measured by a
technique of measuring workpiece deflection would be quite dynamometer and displacement by a dial gauge to determine
useful to verify the compliant tool–workpiece models as characteristic parameters. It was found that the region of stability
discussed in Section 3.1.2. enlarges when the contact damping effect on the tool flank is
Bao et al. [76] distinguished the basic difference between the considered in comparison to that with a sharp tool. It means that
distributions of the probability density function of the vibration the stability against chatter improves as flank wear increases.
signals before and after chatter and that is utilized to detect Rao and Shin [23] collected force, acceleration and surface
chatter in turning. They selected the interval frequency difference texture data to verify the chatter stability predictions of their
‘H’ in the amplitude domain of the dynamic cutting force as a dynamic force model. All the experiments were performed on a
parameter for early chatter stability prediction. This prediction 7 HP engine lathe with a fixed spindle speed drive. Machining
parameter was obtained from the probability density function of tests were carried out by cutting AISI 4140 steel workpieces with
the dynamic signal. It was also not influenced by the cutting uncoated carbide inserts of nose radius 0.8 mm (Kennametal SPG
conditions because it was a relative value and it had greater 422). Force and acceleration data were recorded by a Fourier
prediction accuracy. The transition state defined by the process analyzer, which was followed by frequency response measure-
between stable state and chatter state is assumed to be the ments. The roughness profile for the machined surface was
complex combination of random signal and sine signal. Although recorded for the unstable–stable cases using a Profilometer. The
it was a novel technique with feature extraction in a chatter dynamic force model could predict the stability limit for turning
recognition system, a pattern classifier is required for cutting at large depths of cut as well as finish turning where chatter
state identification. occurs. The dynamic force model was implemented on a compu-
Yeh and Lai [77] developed a chatter monitoring and signal ter to generate time-saving chatter stability predictions. Although
processing system for turning a slender workpiece. In monitoring, the effect of workpiece vibration on cutting dynamics was
the dynamic component of the cutting force was detected and its neglected in the model, this technique is still an effective tool
standard deviation value s was computed through signal proces- for planning and selecting cutting parameters.
sing. Chatter occurrence was judged using the steep increment of Grabec et al. [79] developed a new method for the detection of
the s value. Instead of selecting a simple threshold like Lin and Hu chatter onset based on characterization of changes in process
[78], a double-standard concept was proposed for the threshold dynamics. Model performance was demonstrated by experiments
selection to avoid misjudgments in chatter detection. It was also with turning in which the transition to chatter is caused by the
mentioned that the tool nose run-off will affect the cutting force variation of cutting depth. The signal from the cutting force was
and performance of the machining process. Therefore, the tool characterized by the normalized coarse-grained entropy rate
nose run-off was also selected as one of the control factors in whose value exhibits a drastic drop at the onset of chatter. The
this study. characteristic value of coarse-grained entropy rate was
 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47 37

determined which is insensitive to variation of cutting conditions, dynamics when a flexible workpiece is considered. A tri-axial tool
to automatic online detection of chatter. post-strain gauge dynamometer was used to measure cutting
Dimla and Lister [80] have used tool-post dynamometer as a forces in three directions. Kayhan and Budak [10] used a TCM
force sensor to measure all three cutting force components to find method for the experimental investigation of chatter effects on
the static and dynamic components of the cutting force and tool life. A laser displacement sensor was used to collect vibration
reviewed research work for the force sensors. The authors data during the turning tests. Calibration tests were performed
suggested that the use of the force sensor is vital in the develop- using a force dynamometer to determine the cutting constant.
ment of a TCM system. A 3-axis accelerometer was investigated to Cutting force and displacement data were collected continuously
monitor vibration signals of a turning operation and the conclu- during the tests. The tool dynamics was obtained using impact
sion was drawn that the vibration signals are most sensitive to testing and modal analysis. Impact tests and modal analysis were
tool wear. Time domain analysis established the nature and level also used to determine chatter limits and modal frequencies for
of static force magnitude change while frequency analysis each tool holder length case.
demonstrated the dynamic force signatures’ response to cutting Suzuki et al. [38] verified their SDoF and 2DoF models with
conditions as well as accrued wear levels. This research has found basic plunge cutting experiments and confirmed that the work-
ubiquitous industrial use compared to other research which have piece is significantly flexible in the radial direction and its
been carried out concerning the development of a reliable TCM flexibility depends on the position along the rotation axis, while
system. its natural frequency is unchanged. Transfer functions were
Clancy et al. [81] successfully validated a chatter stability measured at several positions by the impulse response method.
prediction model for a face turning operation using an acceler- It was found that the equivalent transfer function is useful to
ometer by attaching it to the tool shank. A large spike in the estimate the effect of the cross transfer function and the cutting
acceleration spectrum close to the natural frequency was an force ratio on the chatter stability and achieved different stability
indicator of chatter. Ozlu and Budak [36] used a modal setup to limits in comparison to conventional analysis. The vibrations at
measure the transfer functions of the workpiece and the tool on a the cutting positions were measured by an eddy current displace-
conventional manual lathe machine. The modal test setup ment sensor.
consisted of an impact hammer, an accelerometer and a data Taylor et al. [83] investigated the process damping stability of
acquisition system. The collected data was analyzed by CurPro turning difficult-to-cut materials with a custom-built flexible tool
software. This technique is not only useful in studying the holder. The tool displacement was measured using an inductive
influence of the variation of the modal parameters along the tool sensor focused on an aluminum target. Accelerometers were also
axis but it can be applied to varying tool geometries. Altintas et al. used to measure vibrations in the feed and cutting directions.
[56] verified a chatter stability model by using a three component Modal parameters were measured using a modal hammer and the
force sensor and accelerometer. It was found that accurate inductive probe. The cutting stiffness was determined by
prediction of chatter stability at low speeds depends on the performing calibration tests using a rigid tool holder and a
identification of the dynamic force coefficients because they are dynamometer. Storch and Zawada-Tomkiewicz [84] presented
quite sensitive to process parameters. distribution of unit forces on the nose of a tool insert to reveal
Kebdani et al. [27] found natural frequency and the damping conditions for the chip formation on the rake face and to find the
ratio of the tool system by impact testing. Frequency responses machined surface quality on the flank face. Unit force distribution
were obtained by attaching an accelerometer on one side of the and values were established based on force measurements in the
tool. Structural stiffness was obtained by simultaneous measure- orthogonal direction for free and nonfree turning. But the calcu-
ments of displacement and static force applied at the end of the lated and measured unit forces are only useful for single point
workpiece through the tool. The displacement of the tool system cutting with a sharp cutting tool having fixed tool geometry and
was measured by a dial gauge. The cutting stiffness was found by with uniform temperature assumption, which is contrasting to
measuring thrust force for given cutting conditions. The static the industrial conditions. The tool wear will actually change the
force and the thrust force were measured by a dynamometer tool geometry soon after the cutting begins which causes a
connected to the tool system. change in the distribution of unit forces.
Sekar et al. [24] experimentally verified the stability of a Apart from chatter, the cutting forces are also sensitive to
turning process with a tailstock-supported workpiece using the other parameters and can vary with cutting speed, depth of cut
TCM method. To validate the SLD, modal data of the workpiece and work hardness, making correlation with chatter more com-
and the tool were obtained using an ‘Impact hammer’ especially plicated. Vibration measurement is easy to implement but the
designed for experimental modal analysis. Two small piezoelec- recorded signals depend highly on cutting conditions, workpiece
tric accelerometers were installed in two lateral directions. material and machine structure. Although force and vibration
A microprocessor-controlled coupler was used to provide power measurements require very expensive instruments like dynam-
and signal processing. Dynamic cutting forces were recorded with ometers and accelerometers which are sometimes very difficult to
a three component piezoelectric tool dynamometer and a multi- mount on a turning machine due to their configurations, they will
channel charge amplifier to predict the chatter conditions. Serra still be pursued as TCM techniques in future to detect chatter as
et al. [22] carried out experiments on a CNC lathe. To validate the they portray the true nature of the dynamics of the cutting
dynamic instability identification, the direct response of the process.
spindle and cutting tool was measured with six piezoelectric
accelerometers. Use of six accelerometers allowed them to record
as much vibration data as possible from the cutting process to 4.1.2. Sound and acoustic emission (AE) measurements
generate a large number of signal features. Impulse and displace- The sound of a machining process which is usually measured
ment responses were recorded and signal processing was using a microphone can provide valuable information regarding
performed with MATLAB software. Overall, the method was found the process and the condition of the cutting tool. The sound
to be accurate in distinguishing stable and unstable cutting emitted from a machine is usually in the audible range of human
conditions with the help of vibration analysis. ears. A human operator beside the machine can distinguish the
Kotaiah and Srinivas [82] carried out cutting experiments on change in the machining sound induced by machine failures or by
an engine lathe to verify the tool overhang effects on cutting abnormal cutting conditions like chatter. Acoustic Emission can
38 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47

be defined as the transient elastic energy spontaneously released are generated as a result of tool chatter, affect the amount of the
in materials undergoing deformation or fracture or both. The transmitted ultrasound energy into the workpiece material and
energy contained in an AE signal and the rate at which it is amount of the reflected energy. The change in the energy of the
dissipated are strongly dependent on the rate of deformation, the echo signals was directly related to the severity of chatter. The
applied stress and the volume of the participating material [85]. ultrasound sensor was able to detect the first contact of tool–
A metal cutting process itself is a very well-known source of AE. workpiece, tool chipping and flank wear. Budak and Ozlu [35]
AE can detect most of the phenomena in machining including used an accelerometer and AE sensors to verify a multi-dimen-
chatter, although significant data acquisition and signal proces- sional chatter stability model which includes nose radius to the
sing is required. tool geometry. A sound measurement setup was used to measure
Grabec and Leskovar [86] were the first to analyze the sound the chatter frequency for comparing their SDoF and multi-
emitted by the cutting process of an aluminum alloy, and found dimensional models in [37]. Yu et al. [94] found that when
that the spectrum of the audible frequency is discrete, while that chatter occurs, significant vibrations in the system are established
of the ultrasonic range is continuous. The influence of the relevant which can be detected using the sound pressure level from a
cutting parameters on the spectral distribution was studied, and a microphone to determine precise chatter frequency. The micro-
qualitative explanation of the corresponding effects was given. It phone was placed near the tool holder to catch the sound waves
was proposed that AE could possibly be used to evaluate the from the cutting process and it was connected to a frequency
sharpness of a cutting tool. analyzer and a plotter. It was found that there is an increase of
An AE is a sound wave or, more properly, a stress wave that about 20 dB in the sound pressure level as a result of chatter.
travels through a material as a result of some sudden release of Kotaiah and Srinivas [82] used sound signals to record critical
strain energy, according to Li [87]. The majority of AE monitoring chatter length on the workpiece during experiments. The cutting
applications have relied on the RMS value of AE signals. AE point with an abrupt increase in signal was considered as the
derived from metal cutting consists of continuous and transient critical cutting length. Eynian and Altintas [64] detected the onset
signals, which have distinctly different characteristics. Continu- of chatter by monitoring sound pressure measured with a micro-
ous signals are associated with shearing in the primary zone and phone and an accelerometer attached under the tool holder. The
wear on the tool face and flank, while burst or transient signals presence of chatter was recognized when the frequency spectrum
result from either tool fracture or chip breakage. The main had significant strength around the modal frequencies but not at
advantage of AE is that the frequency range of its signals is much the spindle’s rotational frequency, accompanied by high pitch
higher than that of machine vibrations and environmental noises, noise and poor surface finish. Kurata et al. [59] measured sound
and that it is not intrusive in cutting operations. signals to identify process damping coefficient from turning tests.
Liang and Dornfeld [88] suggested possible sources of AE Very recently, Bhuiyan et al. [95] captured AE signals from a
during metal cutting processes: turning process to independently observe only the effect of chip
formation on tool states. It was found that the tool wear, the
(1) Plastic deformation during the cutting process in the plastic deformation of work material and the chip formation are
workpiece; the key source of the AE signal. However, AE was not linked with
(2) Plastic deformation in the chip; the chatter state of the tool.
(3) Frictional contact between the tool flank face and workpiece The observation of the changes in AE signal parameters can
resulting in flank wear; provide a more convenient and accurate method (compared to
(4) Frictional contact between the tool rake face and the chip analytical methods) to determine the onset of chatter as there are
resulting in crater wear; no assumptions considered as in modeling of the system. The use
(5) Collisions between chip and tool; of sound/AE measurement technique in an industrial environ-
(6) Chip breakage; ment is not much popular due to the restrictions imposed by the
(7) Tool fracture. presence of other disturbing noises. Since sound/AE signals are
heavily dependent on process parameters, it is important to carry
Takata et al. [89] and Sata et al. [90] used microphones for out the selection of signal processing methods and signal extrac-
pattern recognition of sound generated in machining operations. tion techniques very carefully.
The speaker dependent isolated word recognition technique was
employed based on the short time spectrum analysis. The experi-
mental system was applied to the monitoring of the operation of a 4.2. Chip analysis technique
vertical machining centre. The results of the experiments showed
considerably high rate of recognition for the movement of the Some researchers have analyzed the chips generated in a
machine and various machining operations including machining turning process to determine stability conditions and to detect
with a broken tool. chatter occurrence. However, the authors of the current paper
The application of AE to the in-process assessment of turning believe that analysis of chip formation could only provide
quality in the context of chatter and tool wear was described by information about chatter after it has actually occurred. So, this
Chung et al. [91]. Chiou et al. [92] used an AE sensor to detect method is unable to predict chatter onset in advance.
chatter in the presence of tool wear. It was found that the RMS Nurulamin [96] studied the mechanism of instability of chip
(Root Mean Square) of the AE signal is quite sensitive to chatter formation on micro section metallographic specimens of chip
and tool wear, because the AE signal characteristics change with roots, received by instantly stopping the cutting process at
varying cutting process mechanics and vibration. An AE sensor different phases of the full cycle of instability as well as on
with an accelerometer was used and successfully detected chatter micro-section metallographic specimens of the chip. On such
frequency, amplitude and effect of tool wear on the process. Lange specimens, with the help of a metallographic microscope and
and Abu-Zahra [93] presented a method for tool chatter monitor- micro-hardness measuring instruments, the grain orientation,
ing using the wavelet analysis of ultrasound waves. Ultrasound borders of different zones and micro hardness were measured
waves were pulsed through the tool towards the nose and are and on their basis, the shear angle, length of different zones and
reflected back off the cutting edge. Fluctuating states of contact contact areas and also the time of each phase of the cycle were
and noncontact between the tool-insert and the workpiece, which determined. It was discovered that physical cause of chatter is the
 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47 39

instability of chip formation and by self excitation between tool network architectures. One identified the system harmonics and
and workpiece at the resonant frequency. another was used to estimate the frequency to analyze the
Tangjitsitcharoen [97,98] presented a method for in-process acceleration signals to predict chatter. For combining these two
monitoring and identification of cutting states for a CNC turning separate procedures, an algorithm was developed to identify
machine. The method utilizes the power spectrum density (PSD) chatter and its frequency. Testing was carried out using a function
of the dynamic cutting force. Experimental results discovered that generator and by online testing in turning operation, where it
there are three types of patterns of PSD when the cutting states could detect unstable vibrations and as a result save substantial
are continuous chip formation, broken chip formation and tool life.
chatter. The broken chip formation was desirable for a stable Tansel [102] demonstrated the use of neural network to
and reliable operation. During continuous chip formation, the identify the dynamics of a 3DoF turning process over a large
dynamic feed force was small and PSD was large when the cutting speed range (50–105 m/min) and to simulate the turn-
frequency was less than 50 Hz. During broken chip formation, a ing process. The model estimates the discrete transfer functions
large varying dynamic feed force was observed with large PSD at used for simulation and/or calculation of frequency domain
chip breaking frequency. And when chatter occurs, the PSD characteristics of the system. Also, the neural network can
obtained was larger than continuous and broken chip formations. represent nonlinear structures better than the conventional
Patwari et al. [99] observed the top and sectional views of time series models and the stability conditions could be more
chips using SEM (scanning electron microscope) and discovered accurately evaluated by using the neural network cutting
that chips produced during turning and thread cutting exhibit dynamics simulator. The accuracy of the predictions was found
identical regularly spaced serrated teeth along the free edge of the to be much greater at higher cutting speeds. The neural network
chip. After analyzing chatter amplitudes it was also found that model also represents the nonlinear characteristics of cutting
chatter appears in the system when the chip serration frequency dynamics, while the time series methods use only the linear
is equal to or an integer multiple of the prominent natural models.
frequency of the system components. Lee et al. [50] developed a model to study the complex and
Nurulamin et al. [100] identified that the chips formed in highly nonlinear process damping force in chatter vibration.
turning, thread-cutting and milling operations show a common A feed-forward neural network was used to model the cutting
type of discreteness in the form of secondary saw teeth. The force components. An algorithm was produced for the calculation
primary saw teeth were identified apart from secondary saw of the volume displaced in the work material. This model can be
teeth and their frequencies. Chips were studied using SEM, optical easily applied to turning, milling and drilling processes. Dimla Jr
microscope and a digital camera. It was found that chip formation et al. [103] reviewed tool condition monitoring techniques which
is unstable due to the formation of secondary saw teeth, primary are mostly developed through the application of neural network
saw teeth and cracks at the boundary between two adjacent and by observing variations in one or more of the process
secondary saw teeth. Chatter appeared in the system when the responses (outputs) related to tool deformation and, conse-
frequency of the chip formation instability becomes approxi- quently, exploited to investigate the aspect of tool wear monitor-
mately equal to or an integer multiple of the prominent natural ing and control. But there is only a brief mention of chatter
frequencies of the system components in a turning process. The detection using neural networks and most of the neural network
tool holder was the prominent system component responsible for based tool condition monitoring systems presented in the litera-
chatter in the turning process. Some researchers still associate ture should be considered offline since they have not been tested
chip formation with the dynamics of the turning process and to or implemented online.
decide chatter conditions. However chip analysis would merely Lange and Abu-Zahra [93] used wavelet packet analysis to
remain the post mortem of the process/behaviour as it could not filter the ultrasound wave signals generated from the turning
predict the stability of the process in advance. process. A multi-layer perceptron (MLP) ANN was employed to
correlate the response of the ultrasound sensor to the acceler-
ometer measurement of tool chatter. The system response to
4.3. Artificial intelligence techniques
various frequency levels of tool chatter could then be investigated
but the chatter frequency could not be measured. Benardos et al.
Several researchers have presented artificial intelligence tech-
[41] used ANN to develop a model to predict the dimensional
niques like Artificial Neural network (ANN), Hidden Markov
deviation of the final part by correlating the cutting parameters
model (HMM) and Fuzzy logic to predict and detect the occur-
and certain workpiece geometrical characteristics with the devia-
rence of chatter by classifying signal features obtained through
tions of the depth of cut.
sensory signals. These artificial intelligence techniques are
Kotaiah et al. [104] studied effects of cutting parameters in
reviewed in this section and Fig. 8 provides information about
orthogonal turning on the critical chatter lengths over the work-
publications for each technique.
piece and the static cutting forces on the tool by a series of
experiments. After measuring the dynamic cutting forces, surface
4.3.1. ANN technique roughness and critical chatter lengths, the relations between the
ANN is an information processing paradigm that is inspired by input and output parameters were established using radial-
the way biological nervous systems, such as the brain process basis function (RBF) neural network model and it was further
information. The key element of this paradigm is the novel employed to genetic algorithms (GA) to optimize the machining
structure of the information processing system. It is composed data. Use of neural network technique in micro-cutting opera-
of a large number of highly interconnected processing elements tions by several researchers is very well summarized by Chae
(neurons) working in unison to solve specific problems. ANN can et al. [105] and the estimation of tool condition in micro-
be used for applications like pattern recognition or data classifi- machining of steel and aluminum has been explained. However,
cation of signal features, through a learning process. chatter detection was not carried out using ANN techniques in
Tansel et al. [101] used a single-sensor input to predict chatter this work. The neural network technique requires extensive
development using neural network. The proposed method experimental data for a specific process and material condition,
successfully identified 98% of the harmonic signals with only 5% which can be inconsistent for different processes, cutting condi-
error. Chatter signals were presented to two MLP-based neural tions and material conditions.
40 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47

The neural network is becoming the most powerful simulation 5. Chatter suppression/control techniques
tool for cutting dynamics with respect to accuracy, flexibility, and
computational speed when synthesized with sophisticated algo- Chatter suppression/control is a very challenging problem in
rithms and multi-processor neural network hardware. turning. The need to develop better techniques for chatter
suppression and control is growing stronger than ever due to
the pressure on manufacturing industries for high productivity,
4.3.2. HMM technique high precision, lower rejection rates and lower production costs.
HMM is extensively used for speech recognition. It is very Chatter suppression/control techniques can be classified into two
suitable for modeling dynamic time series, and has a strong main categories, namely, passive chatter suppression/control and
capability for pattern recognition from abundant information active chatter suppression/control. These chatter suppression/
received from sensor signals. control techniques are reviewed in this section and Fig. 9 provides
Zhang et al. [106] presented a new hybrid HMM–ANN techni- information about publications for each technique.
que for chatter monitoring in a turning process. The hybrid HMM In the passive technique, the objective is to suppress chatter by
and ANN combined advantages of HMM sequential modeling changing the system behaviour. The system behaviour can be
structure and ANN pattern classification to monitor a nonsta- changed or modified by either improving the design of the
tionary turning process. HMM is very suitable for the monitoring machine tool or by using additional devices that can absorb extra
of chatter vibration, however, it has been mostly used to detect energy or disrupt the regenerative effect [9]. These additional
the tool wear and rarely used to detect chatter. devices usually have lower rigidity and are able to damp, reduce
and control the chatter phenomena. Vibration absorbers, friction
dampers, mass dampers or tuned dampers are some of the most
4.3.3. Fuzzy logic technique common devices added to the machine for passive chatter
Fuzzy logic can process information like our brain. Fuzzy logic suppression. Xiao et al. [111] presented a method to suppress
systems base their decision on inputs in the form of linguistic chatter vibration by applying vibration cutting. It was found that
variables derived from membership functions which are formulae the vibration cutting is more stable with respect to conventional
used to determine the fuzzy set to which a value belongs and the cutting as it suppresses chatter vibration by disrupting the
degree of membership in that set as explained by Bojja [107]. regenerative effect. The energy generated from the cutting pro-
These variables are then matched with the preconditions of cess can also be reduced by changing the cutting conditions to
linguistic IF–THEN rules, which are called fuzzy logic rules, and suppress chatter.
the response of each rule is obtained through fuzzy implication. Marui et al. [112] incorporated a friction plate within the
Du et al. [108] presented a study on tool condition monitoring overhanging part of the tool shank in order to improve the
in turning using the fuzzy set theory which was first introduced damping capacity of the system by friction during vibration acting
by Zadeh [109]. Tool conditions like tool chatter, breakage, tool between the inner wall of the hole and the inserted plate surface.
wear were considered. Force, vibration and power sensors were However, the extent of damping capacity improvement is affected
monitored and 11 signature features were selected to describe the by the position of the hole and the interference between the
signature characteristics of various tool conditions. The linear rectangular hole and the inserted plate. Insertion of the friction
fuzzy methodology was compared with several classification plate changed the system behaviour due to the increased damp-
schemes, including the K-mean, the Fisher’s pattern recognition ing and enhanced the stability by suppressing chatter.
methods and fuzzy C-mean method and it was found that results Amongst many passive suppression techniques, dynamic
from the proposed fuzzy method indicate an overall 90% relia- vibration absorber (DVA) or tuned mass damper (TMD) has been
bility for detecting tool conditions. widely used in practical applications [113]. Tobias [5] described a
Tansel et al. [110] proposed S-transformation to prepare 3D few practical techniques in which a vibration absorber is fitted to
plots to display variation of the amplitude of acceleration signals various elements of the machine tool to suppress chatter and to
from a turning operation in the time and frequency domain. improve the process stability. Rivin and Kang [114] proposed a
A frequency–time–damping index plot was obtained from the laminated clamping device made up of steel plates and a hard
S-transformation result. The frequency–time–amplitude charac- rubber visco-elastic material to hold the cutting tool and
teristics of the acceleration were calculated from S-transforma- increased the damping of the system significantly in order to
tion and it was better than Wavelet transformations methods like suppress chatter. Tarng et al. [115] and Lee et al. [116] used a
Dubechies 3, Morlet and short time Fourier transformation (STFT). piezoelectric inertia actuator acting as a tuned vibration absorber
The variance of the damping index in a small band around the to suppress chatter in turning. Tarng et al. [115] manually tuned a
natural frequency of the workpiece was found as the best vibration absorber’s natural frequency to modify the frequency
indicator of chatter. Fuzzy logic controllers were used for auto- response function (FRF) of the cutting tool and to match with
matic chatter detection. The use of a local area network (LAN) was natural frequency of the structure’s target mode, which needs to
proposed to integrate the data collection, computation and be damped. Yang et al. [117] proposed to optimize the negative
dissemination processes to store the vibration history of machin- real part of FRF at the tool–workpiece interface by attaching
ing for critical parts and reporting the results to the operators passive mass dampers to the machine structure and increased
with wireless devices. chatter resistance/stability of the turning process. Wang et al.
The decision making in a fuzzy system is fast due to its [118] proposed a new nonlinear TMD capable of absorbing energy
simplicity but it suffers from the difficulties in selecting suitable via both sliding friction and vibration of its own mass to suppress
membership functions for the target system. Overall ANN tech- chatter in a turning process. The new nonlinear TMD with mass
nique was found to be better and more popular than HMM and ratio of 0.01 improved the critical limiting depth of cut by
Fuzzy techniques due to its trainability, massively parallel struc- 150–180% compared to the undamped system.
ture, higher accuracy of prediction/classification of signal Passive vibration suppression techniques exhibit numerous
features, quick implementation and commercially available ANN advantages like easy implementation, low cost and no need for
hardware and software. ANN dramatically reduces computational external energy. But for good performance, some passive dampers
time in decision making, pattern recognition and simulation require very accurate tuning, which is difficult, due to uncertain-
studies. ties in the machine–tool structure and in the cutting process.
 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47 41

In the active technique, as the name suggests, the chatter avoided. It was interesting to learn that the linear feed of the
vibrations are actively eliminated by continuous monitoring and machine was maintained during the speed change. Tarng et al.
diagnosis of the turning process and by executing necessary [126] presented a technique to reduce regenerative chatter by
changes in the process. Some researchers employed techniques adjusting the spindle speed automatically to an integer ratio of
to disrupt the regenerative effect by actively varying process the chatter frequency. It resulted in a stable cutting process
parameters like speed, feed and depth of cut. Lin and Hu [78] because the phase between the current and previous revolution
proposed an approach in which the feed-rate and the spindle of the workpiece is forced to be zero. Soliman and Ismail [127]
speed were varied to suppress chatter. Mei et al. [119] varied the designed and implemented a PD (Proportional-Derivative) fuzzy
rake and clearance angles of the cutting tool in order to eliminate logic controller to suppress chatter. Chatter was detected online
the onset of chatter. Recently, Frumusanu et al. [120] presented a using an R-value indicator calculated from the cutting force
stability intelligent control technique for turning. The technique components at low and high frequencies. The difficulties in
involved online monitoring of the cutting force signal. The mean implementing the SSV technique due to the inertia of the spindle
amplitude of this signal in frequency domain was extracted as a have been overcome. This technique was improved by ramping
dedicated feature. A new stability control strategy and system for the spindle speed for chatter suppression [128]. The main
turning were proposed by assessing the machining system oper- advantage of this online technique was that it could monitor a
ating point position relative to the stability limit proximity using chatter indicator without stopping the machine. Al-Regib et al.
this feature and permanently referring the current feature value [129] developed a systematic procedure for optimal selection of
to the limits of an admissible interval for their variation. spindle speed variation, amplitude and frequency in a turning
A dedicated control model with sequential character was used process. A sinusoidal SSV technique was employed in order to
to take the appropriate decisions concerning the workpiece disrupt the mechanism of regenerative chatter. It may be quite
rotation speed adjustment, if necessary. The chatter onset was difficult to use this technique in industrial applications due to the
successfully avoided. However, the experiments were conducted limitations of spindle dynamics. The technique requires tremen-
in a laboratory environment and need to be tested in a practical dous torque from the machine to overcome the inertia of the
environment. drive system. Experimental turning tests were carried out to
Another technique for vibration suppression is using a delayed verify the effectiveness of the technique but these experimental
feedback control vibration absorber. The time delay usually validations were made only for low spindle speeds. Wu et al.
appears due to the inherent nature of the dynamics of the system. [130] applied variable speed machining (VSM) technique to
A delay can be efficiently used to control motions of a system noncircular turning to increase the process stability in which
from chaotic motion to the ordered motion and vice versa. Olgac the cutting tool is driven by a fast tool servo and performs
and Holm-Hansen [121] introduced a delayed resonator to machining by dynamically varying the depth of cut. A closed loop
provide delayed position feedback control to dynamical struc- dynamic model involving strong dynamic feedback between the
tures. This technique offers advantages like real time tunability, machining process and the fast tool servo was developed. The
wide range of frequency, perfect tonal suppression and simplicity spectral radius analysis was used to tract the system stability. A
of control while eliminating the tonal vibrations of the system. criterion of the VSM stability index is used to evaluate the
Olgac and Hosek [122] proposed a root locus method with time quantitative effects of VSM on noncircular turning systems and
delays for active suppression of chatter in turning using a delayed to design optimal VSM trajectory parameters. It was claimed that
resonator. However it is not quite clear if face turning instead of this technique could be applied to the stability analysis of other
longitudinal turning is modeled. The time delay unavoidably periodical time-varying discrete systems. It was found that the
results from the regenerative process and it is a major factor that effect on stability is also constrained by the spindle drive system
causes chatter in turning. and the fast tool servo controller. Zhang et al. [131] developed a
Another technique for chatter elimination is Spindle Speed chatter model using a nonlinear delay differential equation and
Variation (SSV), where the spindle speed is varied continuously proposed a formula to select SSV amplitude based on the internal
which actually disrupts the regenerative effect. This method of energy analysis of the SSV.
continuous modulation of the spindle speed is attracting increas- Recently, Wu and Chen [132] applied SSV to noncircular
ing attention because of its simplicity and effectiveness in chatter turning. The stability charts both for constant speed machining
suppression. The stability of a machine-tool system can be (CSM) and for SSV were computed and compared for a turning
enhanced by the right selection of constant spindle speed and process. It was found that the regenerative chatter vibrations
the stability can be further increased with the use of SSV appearing during CSM could be eliminated by continuously
technique. Weck et al. [123] first presented an idea that by varying the spindle speed. It was also found that the spindle
changing the spindle speed to the stable part of the stability lobe speed amplitude, RVA, has significantly higher influence on
diagram it is possible to stabilize an unstable machining opera- process stability than spindle speed variation frequency, RVF. So
tion. However the online chatter avoidance method was proposed a larger value of RVA should be considered while selecting spindle
for a face-milling operation. Tsao et al. [124] modeled a system speed variation parameters.
with variable speed using the spindle angular position as an Although SSV technique seems easily applicable, the success
independent variable. It has resulted in a time varying system is limited to only short-time operations where chatter vibration
with a constant delay length. The analysis of such a system has not been developed yet. There are some major limitations
becomes easier than a system with fixed coefficients and a of SSV technique for industrial applications. In order to disrupt
variable delay length. The stability of the system was analyzed the regenerative effect, the spindle speed variation should be
using a finite difference scheme. However the computed stability extremely fast, which may not be possible due to high momen-
was found to be sensitive to the number of points used in the tum of the spindle system. SSV technique is also not very
discretization and the derived conclusions seem to be ambiguous. efficient since a large portion of energy is consumed to accel-
Liao and Young [125] proposed an online chatter control erate and decelerate the spindle. A slight disturbance of the
technique with the self-setup of spindle speed. The cutting force spindle speed at high machining speeds may result in severe
was recorded with a dynamometer and the chatter frequency was unbalance and instability of the spindle system leading to
identified using spectrum analysis. The chatter frequency was catastrophic failures of machine–tool components. The SSV
used to calculate new spindle speed at which chatter could be technique even adds additional cost to the machining. Due to
42 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47

these drawbacks of SSV technique, its widespread industrial There are numerous advantages of the active suppression
application has not yet emerged. technique. For example, the active suppression technique does
Many researchers introduced various active materials to sup- not require a model of the system and it is robust if a collocated
press chatter. Active materials exhibit the ability to change sensor and actuator configuration is used. This makes it a
mechanical force and motion into other forms of energy. These potential candidate for chatter control in machining operations.
active elements are usually integrated into a structure or machine Both milling and turning operations are associated with large
tool in an unobtrusive manner and are intended to inject energy amplitude vibrations and the actuator is required to be immen-
into the system in order to counteract the regenerative chatter sely strong to have a control effect on the system. Thus hydraulic
vibrations. Due to the outstanding ability to sense and actuate in or inertial actuators are more suitable for the application of active
critical situations, these elements are often termed as smart damping in this case. It was also observed that the active
materials. Smart materials are those that exhibit piezoelectric suppression technique is more efficient in enhancing the stability
effects, magnetostrictive effects, as well as materials such as of the tool in the low stability regions than the high stability ones.
magnetorheological (MR) and electrorheological (ER) fluids, ionic Application of an active technique raises these low stability
fluids and shape memory alloys. Park et al. [133] rigorously regions, enabling one to machine with higher values of axial
reviewed such active materials with a special focus on piezo- depth of cut in a region, less vulnerable to changes in the system
electric and magnetostrictive materials and their applications in dynamics. However, most of the active systems have few draw-
active suppression of chatter for turning and other cutting backs. The active systems require a second vibration source to
processes. Choudhury et al. [134] proposed an online tool vibra- increase the total energy of the vibrating waves. Most of the
tion suppression system with a piezoelectric actuator mounted on active chatter control systems are limited to low spindle speeds.
the tool post. The relative vibrations between the tool and the Active systems also require more complex hardware and software
workpiece were monitored using optical sensors and whenever and are more expensive compared to passive systems.
these vibrations cause regenerative effect, an opposing force was Despite the potential advantages of fully active techniques,
generated by a vibrator-exciter using a close-loop control method passive tuned vibration absorbers remain a useful device for
to stabilize the system. improving the chatter stability of a turning process, due to their
Pan and Su [135] have introduced a piezoelectric actuator lower cost and complexity. For passive and active vibration
mounted on to a tool holder for chatter suppression. The actuator absorbers the performance mostly depends on correct tuning of
regulates the machine displacement with a robust adaptive the physical parameters. Although active control techniques have
controller which accounts for hysteretic nonlinearity of the become increasingly popular which can be observed from Fig. 9,
turning process. It was claimed that the technique has signifi- passive control techniques remain an important and effective
cantly reduced the chatter phenomena. Chiou et al. [136] used vibration control tool. The passive control techniques never lead
active electrostatic and piezoelectric spindle bearing support to the controlled system to instability, while the active control
change the FRF and the modal properties of the structure to techniques can make the system unstable. Due to the significant
suppress chatter. However the algorithm proposed here requires advancements in new electronic control technologies, the future
extensive computer simulation to change the cutting force varia- chatter control techniques should be an amalgamation of passive
tion when mode shape changes occur in the machine structure. and active techniques, where both the control techniques would
Ganguli et al. [137] proposed an active damping strategy with be applied simultaneously to control chatter.
collocated sensor and actuator configuration for regenerative
chatter stabilization. The effect of active damping on regenerative
chatter instability was demonstrated via a mechatronic simulator 6. Review of chatter and tool wear relationship research
for a turning operation. It was found that the active damping by
velocity feedback does not require a very accurate model of the Tool wear and chatter vibrations have been major issues in
structure and can be focused as a broadband vibration control almost all metal cutting processes since the beginning of the
strategy. It was observed that active damping changes the machining era. The relationship between these two is very
frequency of chatter and that active damping is more efficient complex and yet to be fully established. Researchers have
in enhancing the stability of the tool in the low stability regions included tool wear in the modeling of chatter vibrations in a
than the high stability ones. Ganguli et al. [138] explained that turning process, but to the authors’ knowledge, no work has been
different spindle speeds caused changes in the system damping, reported which establishes a theoretical relationship between the
resulting in different level of stability limits at different spindle two, especially the effect of chatter vibrations on tool wear.
speeds. The chip thickness in the turning process was dependent Tobias [7] explained the detrimental effect of vibration on tool
on the damping and the spindle speed. So active damping with life and argued that in the presence of vibration the cutting speed
velocity feedback was selected as a chatter control strategy. The and the chip cross-section vary and this is bound to affect tool life.
plausible adaptive control strategy based on relatively short time The magnitude of this effect is surprisingly very large, even when
series provides deeper understanding of the control process. impact loading of the tool is excluded. The effect of vibration on
However the scope of this strategy to enhance the stability limits the life of single pointed cutting tools can be theoretically
was limited to low stability regions of the SLD. Chen and Knospe expressed as a ratio, with grossly simplifying assumptions as [7]:
[139] presented three different chatter control techniques dedi-
T d =T o ¼ 2=½1þ ðAo=v0 Þn þ ½1ðAo=v0 Þn ð10Þ
cated to the turning process: speed-independent control, speed-
specified control and speed-interval control. An active magnetic where, Td is the tool life under vibrating conditions, T0 is the tool
bearing (AMB) was connected with the cutter for actuation to life under vibration-free conditions, A is the amplitude of vibra-
maximize the damping effect and enhance cutting process stability. tion, v0 is the nominal cutting speed, o is the frequency of
It was shown that significant improvement in tailoring the stability vibration in radian/sec, n is the constant for a given set conditions.
lobes can be obtained using dedicated controllers, obtained via The constant n was found experimentally in the range of 5 to
synthesis, as compared to proportional-integral-differential (PID) 10 by Opitz and Salje [140]. Eq. (10) was tested experimentally for
controllers. The magnetic levitation system like this can be imple- a case when the chatter amplitude reached its maximum value of
mented for many engineering applications, such as vibration isola- A¼v0/o and n ¼3, when Eq. (10) has Td/T0 ¼1/4. In subsequent
tion, frictionless bearings and fast-tool servo systems. experiments a larger reduction of tool life was observed. The
 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47 43

estimates obtained with the help of Eq. (10) appear to be always used as the tool life criteria as it was a fine turning operation. It
on the conservative side, particularly at high cutting speeds and was found that chatter results in 50 to 80% reduction in tool life.
high chatter frequencies. Larger tool life reductions were also Significant reduction in tool life was observed at higher cutting
expected since the value of n is usually between 5 and 10 for speeds, lower tool stiffness and higher vibration amplitudes. This
tungsten carbide and 6–7 for high speed tools, but may be as result is found for varying rigidity of the tool and they rely
large as 25. entirely on experimental analysis. Chatter stability was not found
Tobias [7] also presented problems in this field which needs analytically here. Tool rake angle can be taken into account for
attention. It is not known whether the tool life is affected equally this investigation.
by all types of vibration, i.e., whether the direction of the relative From the limited literature available on the relationship
tool and workpiece motion is of any significance and whether all between chatter and tool wear, it is clear that the estimation of
these vibrations have the same detrimental effect on tool life. Eq. tool wear and tool life is very crucial for machining processes.
(10) is not yet compared with other analytical methods to verify Chatter vibrations adversely affect tool wear and shorten the tool
tool life under self-excited chatter vibrations. Tlusty [30] found life. The complex relationship between them is yet to be solved.
that the flank wear flat is critical in positive damping in the
occurrence of self-excited vibrations.
Matsumoto et al. [141] presented a method for tool wear
monitoring using AE in the presence of chatter vibration in a 7. Conclusion
turning process. The flank wear was calculated using a statistical
model which uses RMS value of the AE signal and the cutting Although a turning process has a 3D configuration, the chatter
speed as variables. It was found that the AE signal is influenced by stability predictions with single or two degree of freedom models
tool vibration, especially during chatter. The tool vibration mon- give satisfactory prediction results. SLDs are the most convenient
itored and analyzed in this article refers to primary chatter rather way for out-of process prediction of chatter vibrations, because of
than secondary (regenerative) chatter. their construction simplicity, clarity of prediction and popularity
Chiou et al. [53] demonstrated that chatter instability is among researchers till date. Even SLDs generated using a simple
delayed to a greater overhang distance as a result of flank wear SDoF orthogonal turning model also give satisfactory prediction
and chatter limit increases especially at lower cutting speeds, as accuracy and result. It is better to avoid chatter before it occurs by
the tool wear increases. Chiou et al. [28] analyzed the chatter disrupting the regenerative effect as discussed in Section 5. If it
behaviour for a slender cutting tool in turning in the presence of cannot be avoided, it should be suppressed passively by carefully
wear flat on the tool flank. The mechanism of a self-excited designing/modifying the machine tool structure or by implement-
vibration development process with tool wear effect was studied ing an effective active control technique simultaneously. After
by comparing chatter stability for a fresh and worn cutting tool. It carefully reviewing the literature for chatter vibrations and tool
was found that the chatter stability increases as the tool wear flat wear/life, most of the literature has investigated the effect of tool
of the cutting tool enlarges because of increased damping in the wear on chatter vibrations. The literature on the effect of chatter
system. vibration on tool life is very limited. The effect of chatter
Chiou and Liang [142] found that chatter frequencies can also vibrations on tool life by considering workpiece flexibility is also
be employed to monitor tool wear since they correlate with the yet to be established.
tool flank wear. Chiou and Liang [92] analyzed the AE in chatter Tool chatter/wear state estimation can be accomplished by
vibration with tool wear effect in turning. The AE generated from analyzing cutting forces and vibration signals obtained from
the sliding contact on the flank wear flat during chatter was various sensors. Tool wear can be measured directly by using a
investigated based on the energy dissipation principle. The pre- microscope. Tool life can be calculated using a tool life criterion
dicted amplitudes of chatter RMS AE signals were experimentally which is mostly based on flank wear width. A maximum flank
verified with fresh and worn tools. Clancy and Shin [54] devel- wear width of 0.2 mm can be used as the tool life criteria.
oped a chatter stability prediction model including tool wear One scope for research is to establish a theoretical relationship
effect. A direct relationship between flank wear and stability limit between chatter vibration and tool wear which shows effects of
was expressed by them. It was found that the presence of wear on chatter vibrations on tool wear analytically. To establish this
the tool raises the limit of stability and allows for stable cutting at relationship, tool wear has to be included in the mathematical
larger depths of cut. Fofana et al. [55] investigated machining model of the turning process initially. Once this theory is
stability in turning by using progressively worn tool inserts. It established, effects of self-excited chatter vibrations on tool wear
was demonstrated that tool wear and dynamic instability are can be experimentally investigated to verify and predict accurate
both due to the combined effect of the contact and friction tool life using TCM methods. Such research is currently under way
mechanisms between tool–workpiece, tool–chip and workpiece– at the University of Western Australia.
tool–machine interactions.
Lu et al. [143] presented the effect of a worn tool on the
dynamics of the cutting process by investigating sound genera- Acknowledgments
tion during surface turning. The results show that as tool wear
increases, the spectral distribution and displacement and the The authors would like to thank the CRC for Infrastructure and
excitation force shift. Engineering Asset Management (CIEAM), established and sup-
Initial attempts of investigating the effects of chatter vibra- ported under The Australian Government’s Cooperative Research
tions on tool life were carried out by Kayhan and Budak [10,144] Centers program for funding and supporting this research.
who investigated the effects of chatter vibrations on tool wear
and tool life experimentally. An orthogonal turning operation is
considered in that work, which assumes zero rake-angle for the
tool and a rigid workpiece. The change in tool life under chatter Appendix A. Publications on different chatter stability
vibrations compared to the stable cutting process was deter- prediction techniques
mined. The tool life was determined by measuring flank wear
using a microscope and a maximum wear land of 0.2 mm was See Table A1.
44 M. Siddhpura, R. Paurobally / International Journal of Machine Tools & Manufacture 61 (2012) 27–47

Table A1

Sr. no. Prediction technique Publications Number of publications

1 SLDs [6], [14], [31], [32], [35], [38], [40], [42,43], [44], [45], [24], 29
[49], [51], [28], [54], [56], [57], [58], [59], [60], [63], [64], [25], [66], [71], [22], [83], [94]
2 Nyquist plots [6], [56], [61], [62], [63], [64], [25], [65] 8
3 Finite element method [45], [63], [65], [66], [67], [82] 6

Table B1

Sr. no. Detection technique Publications Number of Publications

1 Signal processing [2], [10], [13], [19], [31], [35], [36], [38], [40], [24], [45], [50], 64
[51], [52], [53], [28], [54], [55], [56], [58], [59], [61], [62], [64],
[25], [66], [69], [70], [71], [75], [76], [77], [78], [26], [23], [79], [80],
[81], [27], [22], [82], [83], [86], [88], [89], [90], [91], [92], [93], [94],
[95], [96], [97], [98], [99], [100], [101], [102], [104], [106], [110], [141], [142], [144].
2 Chip analysis [95], [96], [97], [98], [99], [100] 6
3 Artificial intelligence [41], [50], [93], [101], [102], [104], [106], [108], [109], [110] 10

Table C1

Sr. no. Signal acquisition technique Publications Number of publications

1 Force measurement [2], [10], [13], [19], [31], [24], [45], [50], [51], [52], [53], [28], [54], [55], [56], 45
[58], [59], [61], [62], [64], [69], [70], [71], [75], [76], [77], [78], [26], [23], [79],
[80] [27], [82], [83], [84], [86], [96], [97], [98], [102], [104], [108], [141], [142], [144].
2 Vibration measurement [2], [10], [31],[35], [36], [38], [40], [45], [24], [50], [53], [28], [54], [56], [58], [59], [62], 44
[64], [25], [66], [71], [75], [78], [26], [23], [80], [81], [27], [22], [83], [92], [93], [94], [96],
[99], [100], [101], [102], [106], [108], [110], [141], [142], [144].
3 Acoustic/sound measurement [35], [36], [59], [64], [25], [75], [82], [86], [88], [89], [90], [91], [92], [93], [94], [95], [141] 17

Table D1 Appendix E. Publications featuring chatter control techniques

Sr. Artificial intelligence Publications Number of

See Table E1.
no. technique publications

1 ANN [41], [50], [93], [101], [102], 7

[104], [106]
2 HMM [106]. 1
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