Snaking chatter: Mechanism and mitigation

This research investigated snaking chatter in grooving blades that causes an inconsistent increase in groove width relative to the tool width, often exceeding tolerance limits in precision applications. Contrary to the suggestion in the literature attributing snaking chatter to mode coupling, this study proposed and verified the hypothesis that it arises instead from regenerative effects on the side walls of the machined groove. With the application of a conventional stability-based process design shown infeasible in addressing snaking chatter, a counterintuitive mitigation strategy that concomitantly delivers a 450% increase in the material removal rate over the state of the art is demonstrated. • Snaking chatter affects accuracy and finish in grooving operations. • It occurs when grooving at speeds over ∼ 200 m/min. • Snaking and diametrical chatter are mutually exclusive. • Snaking chatter stems from regeneration, not mode coupling. • This chatter is mitigated by decreasing corner radius or increasing infeed.