We have tool chatter specialists based across the U.S. in Detroit, Las Vegas, Charlotte, and Tampa.
Chatter is a common phenomenon in endmilling, and is even more prevalent with high-speed spindles, longer tools, higher depth of cuts, and hard materials. Most chatter as described in industy is Self-Excited vibration that is non-linear caused by too much Gain (Depth of Cut) at a given RPM for the given tool stack-up (tool/holder/spindle/machine). The most effective method to eliminate chatter while maintaining high productivity is using a Stability Diagram. Stability Diagrams for metal-cutting were developed in the 1950s and have become more mainstream since the 1980s with the increase in high-speed CNC machines.
The orginal theory was developed for turning, and is still used today, but is not as common as endmilling. Boring has been more successful in recent years due to higher speed CNC machines, and has become our 2nd most common process, while turning is 3rd.
These have been the most difficult to predict for researchers; however, the majority of our past research was in these application, so we have consulted numerous companies with success in improving hole roundness and chatter issues.