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Last updated: 11/16/2022

Mill - Chatter - Test Cut Procedure

AD0647

Mill - Chatter - Test Cut Procedure - Intro

Demo Description:

Use the following test kit and procedure to determine the root cause of the mill chatter.

Perform all troubleshooting listed in the Mill chatter troubleshooting guide.

MILL Chatter Troubleshooting

In addition to the inspections listed, perform the following:

After checking the above and if the chatter continues, gather the tools and parts listed below and run the Mill Chatter test cut program. This is a proven program and can be used on the following mill machines:

  • VF-1 to VF-14
  • DM
  • Mini Mill
  • Super Mini Mill
  • TM

Part Program:

O00011.nc

Mill - Chatter - Test Cut Procedure - Equipment List

Part Number Quantity Description
99-05-0090 1 Haas Riser For 5" Self Centering Vise
99-05-0004 1 5" Manual Self Centering Vise
99-03-0573 2 ½” End Mill 3 Flute With .030" Radius
99-01-0159 1 45 Degree Small Chamfer Mill
99-02-0505 1 Small Chamfer Mill Insert
99-04-0004 1 CAT40 ¾” End Mill Holder
99-04-0011 1 CAT40 ER32 Collet Chuck 4” Gage Length
99-04-0006 1 CAT40 ER16 Collet Chuck 2.5” Gage Length
99-04-0200 1 CAT40 Solid Pull Stud (10 pack)
99-04-0250 1 ER-32 Collet 13
99-04-0218 1 ER-16 Collet 4
99-03-2088 2 1/8” Ball End Mill
N/A 1 6061 Aluminum 3 Inch x 3 Inch Bar Cut To 0.75 Inch

Mill - Chatter - Test Cut Procedure - Tool List

Tool Number 1:

Cutter Type: ½” End Mill 3 Flute with .030" Radius

Holder Type: ER Collet

RPM: 10,000

Number of  Flutes: 3

Minimum Working Length: 1.9"

Haas Tool PN: 03-0573

Haas Tool Holder PN: 04-0011

Haas Collet PN: 04-0250

Haas Insert PN: N/A

Tool Number 2:

Cutter Type: ” ¾” Chamfer Tool

Holder Type: Weldon

RPM: 10,000

Number of  Flutes: 1

Minimum Working Length: 2.75"

Haas Tool PN: 01-0159

Haas Tool Holder PN: 04-0200

Haas Collet PN: N/A

Haas Insert PN: 02-0505

Mill - Chatter - Test Cut Procedure - Setup

A vise of their choice.

The outside profile is .500” deep so they should grip on .150-.200”,  .200” is max.

Set G54 Offset:

Bolt the vise to the center of the table as show in photo. Part center must be within 2 inches of the center of the table.

  • Set tool offsets off top of material
  • Set G54 X0 Y0 to center of material
  • Set G54 Z = Zero

1

With the part in the vise, use a indicator to measure the step between the two tool paths.

Measure the step on either side of the pocket.

2

Measure these two locations on all four sides of the part and use the Y+ and X+ arrows to record the measurements below.

If there is a step out from the top surface to the bottom surface, record a positive value. If there is a step in from the top surface to the bottom surface, record a negative value.

Note: This step should be less than 0.001”.

  Left Side Right Side
X+    
X-    
Y+    
Y-    

3

Adjust setting 255 MRZP X OFFSET or settings 300 MRZP X OFFSET MASTER and setting 303 MRZP X AXIS SLAVE until the X+ and X- results match.

  • If the X+ side has a positive step and the X- side has a negative step, adjust these settings in the positive direction by half the difference.
  • If the X+ side has a negative step and the X- side has a positive step, adjust these settings in the negative direction by half the difference.

Adjust setting 256 MRZP Y OFFSET or setting 304 MRZP Y AXIS SLAVE until the Y+ and Y- results match.

  • If the Y+ side has a positive step and the Y- side has a negative step, adjust these settings in the positive direction by half the difference.
  • If the Y+ side has a negative step and the Y- side has a positive step, adjust these settings in the negative direction by half the difference.

Once all four sides have the same step, adjust setting 257 MRZP Z OFFSET or setting 302 MRZP Z AXIS MASTER.

  • If all four sides have a negative step, adjust these settings in the negative direction.
  • If all four sides have a positive step, adjust these settings in the positive direction.

The tool length offset can also be used to adjust the step on all four sides of the part. If a large adjustment is needed, you need to make sure the probe calibration was done correctly.

4

With a micrometer, measure the distance between the top face and pocket. Measure in two locations, the left and right side of the pocket. Record the measured values for all four sides of the part.

This distance should be 0.625” +/- .001”

  Left Side Right Side
X+    
X-    
Y+    
Y-    

5

If this distance is not 0.625” +/- .001” there could be a problem with the machine geometry.

  1. Check to make sure the B axis is going to B90 by running an indicator along the Z axis on the face of the table at B90. This should measure less than +/- .003” over 10.0”

  2. Check to make sure the platter is flat at B0 by running an indicator along the X axis on the face of the table at B0. See the UMC inspection report. This should measure less than +/- .001” over 20”

  3. If the distance is different between the left and right measurement, check the geometry by running an indicator along the Y axis on the face of the platter at B90 and B-90. See the UMC inspection report. This should measure less than +/- .001” over 20.0”

  4. If the 0.625” distance is different on the four sides of the part, the table could be running out as the C axis rotates, check the face of the platter at C0, C90, C180, C270. See the UMC inspection report. Platter face runout not to exceed .0005”.

6

With a micrometer, measure the distance between the side face and pocket. Measure in two locations, the left and right side of the pocket. Record the measured values for all four sides of the part.

This distance should be 0.625” +/- .001”

  Left Side Right Side
X+    
X-    
Y+    
Y-    

7

These values should be correct if the values in Step 3 are set correctly.

If you are seeing a difference between the left and right side measurements, make sure the X axis is perpendicular to the B axis centerline. This can be done by zeroing an indicator on the front of the part at B0 & C0. Then rotating the B axis to B90 and touching the indicator on the front of the part to see if the front of the part is moving along the Y axis as the B axis tilts. The measured difference between these two points should not exceed .002”.

If you have any problems adjusting the values in these three steps, you will need to fill out a full inspection report and adjust the machine geometry as needed.