1. Presented By: Manufacturing Laboratories, Inc.
Overview
Frequency Response Function (FRF) Stability Map
Presented By:
Manufacturing Laboratories, Inc.

2. Manufacturing Laboratories, Inc.
Purpose of Software
To predict, measure, avoid and control machining Vibrations.
Uses common vibration measuring techniques.
Applies them specifically to the machining process.
MetalMAX Training
Manufacturing Laboratories, Inc.

3. Problems With Today’s Machining (Dynamics)
All machines and tool stack-ups exhibit dynamic characteristics that will impact the cutting process.
Machining by definition is a dynamic process.
Dynamic Characteristics Limit Machining Performance (Ti vs AL).
These characteristics can vary significantly and can be difficult to predict reliably. Measurement is required.
Primary contributor for cutter failure, spindle failure, limits machining capabilities, etc.
Theory and understanding well known by many MR&D Depts. and Universities but only recently
gaining awareness and
acceptance on shop floors.
MetalMAX Training
Manufacturing Laboratories, Inc.

4. What Is High-Performance (HP) Machining?
There are many definitions:
Cutting speed
s(m/min)=pd(m/rot)n(rot/min)
Spindle speed or DN
DN = bearing bore diameter x spindle speed
Torque and Power
others
All of the definitions of high-performance machining are correct in some context.
High-Power is a natural artifact of high-speed.
Power = Torque x speed
MetalMAX Training
Manufacturing Laboratories, Inc.

5. Added considerations for High-Performance (HP) Machining
We have the additional influence of machining feed rates.
What is the “average” feed rate.
Chip-thinning
Surface area
MetalMAX Training
Manufacturing Laboratories, Inc.

6. What Limits HP-HS Machining Productivity?
Different types of machining operations have different limitations.
HP-HS machining may be limited by:
The onset of chatter
Tool-work piece materials
Available power
Tool geometry
Work piece geometry
Controller or servo performance (acc-dec)
Inadequate knowledge about machine capabilities
MetalMAX Training
Manufacturing Laboratories, Inc.

7. Manufacturing Laboratories, Inc.
Chatter Limitations
Particularly in high speed operations where the objective is to have the metal removal rate as high as possible, the onset of chatter will be a limiting factor.
Chatter arises due to insufficient dynamic stiffness
Long slender tools
Small diameter spindles (DN limitation)
Flexible work pieces (although the selection of a tool path can avoid this in most cases)
MetalMAX Training
Manufacturing Laboratories, Inc.

8. Tool-Work piece Material Limitations
With work piece materials such as aluminum, the availability of a tool material is not a limitation. Tools are available which can tolerate the melting temperature of aluminum.
With hard steels, and even more so with titanium, maintaining acceptable tool life is a major problem. There has been some success with light cuts.
MetalMAX Training
Manufacturing Laboratories, Inc.

9. Manufacturing Laboratories, Inc.
Power Limitations
In some cases where the machine-tool-work piece combination is dynamically stiff enough, the cutting operation may be limited by the available power.
Even for the stiffest machines, there are usually some tools which are not power limited.
MetalMAX Training
Manufacturing Laboratories, Inc.

10. Tool Geometry Limitations
In cases where the dynamic stiffness and power are sufficient, the cutting operation may be limited by the tool configuration (the length of the cutting edge or tool diameter, for example).
Cutting edge geometry may be dictated by material property characteristics, thermal behavior, shearing, etc.
MetalMAX Training
Manufacturing Laboratories, Inc.

11. Manufacturing Laboratories, Inc.
Work piece Geometry
In some instances (many die and mold applications), the geometry of the cut is dictated by the desired work piece geometry. For example, the step-over dimension may be limited. In such cases, most of the machining can happen well below the available power.
MetalMAX Training
Manufacturing Laboratories, Inc.

12. Controller or Servo Performance Limitations
Especially for complex geometries, the block throughput rate of the controller can be a limiting factor.
Some easy tests exist
As the speed of the axis motions increase, the dynamic performance of the servos become more significant
High accelerations/decelerations (acc/dec)
Lightweight yet stiff moving elements
Look-ahead or feed forward control
MetalMAX Training
Manufacturing Laboratories, Inc.

13. Knowledge Limitations
A lack of understanding of high speed machine capabilities frequently leads to under-utilization of such machines.
A large, traditional experience base does not exist for high speed machine tool use.
Many high speed phenomena are counter-intuitive for users accustomed to conventional speed machines.
An acceptable part program is usually not the optimal part program.
The programmer needs the machine performance information at the time that the program is written.
MetalMAX Training
Manufacturing Laboratories, Inc.

14. 3 Knowledge Possibilities Exist
You understand the performance capabilities of your machine very well and write part programs respecting the limitations. Or
You fight chatter problems every day.
You are under-utilizing your machine.
MetalMAX Training
Manufacturing Laboratories, Inc.

15. Manufacturing Laboratories, Inc.
Which Qualities Of High-Performance High-Speed Machines Are Most Important?
Spindle Speed alone is not enough.
High power alone is not enough.
Fast motions or tool changes alone are not enough.
High performance controllers alone are not enough.
Advanced tool materials alone are not enough.
Certainly, these things are important, but…..
MetalMAX Training
Manufacturing Laboratories, Inc.

16. Manufacturing Laboratories, Inc.
For reasons which will become apparent, the definition we will use is:
“High-speed (HS-HP) machining occurs when the tooth passing frequency approaches the dominant natural frequency of the system”.
-Scott Smith, UNCC
MetalMAX Training
Manufacturing Laboratories, Inc.

17. What Is Different About HP-HS Machining?
HP-HS machining is different from conventional machining, particularly in the strong influence of the dynamic characteristics of the machine-tool-work piece system on cutting performance.
In HP-HS machining, the metal removal rate (MRR) is usually limited by the onset of “chatter”.
Success in HP-HS machining depends heavily on the ability to recognize and deal with dynamic problems.
Selection of an appropriate spindle speed and depth-of-cut is extremely important and not obvious.
MetalMAX Training
Manufacturing Laboratories, Inc.

18. What Kinds of Parts Can Benefit From High Speed Machining?
Parts which have a large volume of material to be removed.
Aluminum and cast iron parts especially, but also hard materials such as dies and molds.
Parts with thin structures.
Parts which conventionally spend a long time on the machine either due to large metal removal or large surface areas to be machined.
Short runs, or frequently changed designs.
Many others.
MetalMAX Training
Manufacturing Laboratories, Inc.

19. Manufacturing Laboratories, Inc.
Pocketed and Thin Section Parts
MetalMAX Training
Manufacturing Laboratories, Inc.

20. Manufacturing Laboratories, Inc.
Monolithic Structures (formerly stack-ups)
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Manufacturing Laboratories, Inc.

21. Shop Floor Friendly Approach
Supply a complete solution to the
problems with dynamics and
machining.
Model and predict dynamic behavior
and its affect on the cutting process.
Effectively measure and adjust to
unexpected changes.
Maximize Cutting performance (MMR)
Simplify analysis of machine tools and cutters.
Distill technology down to its most essential parts (measurement and prediction).
Machine a part right the first time!
MetalMAX Training
Manufacturing Laboratories, Inc.

22. Exactly what are we talking about?
Methods for obtaining information about the cutting process dynamics and quickly utilizing this information to maximize cutting performance.
Currently available by various means.
Applied in a way for maximum usability.
Our goal is to maximize metal removal rate and reduce or eliminate detrimental vibrations.
We want to utilize basic frequency analysis at the machine or on the shop floor (machinists, NC programmers, process planners, manufacturing engineers) to improve process setup, correct problems when they occur, and objectively evaluate performance.
MetalMAX Training
Manufacturing Laboratories, Inc.

23. Manufacturing Laboratories, Inc.
What are we evaluating?
Design Parameters Frequency (fn), Stiffness (k) and damping (damping ratio ). They do not change over time or with load.
Dynamic stiffness (~2k) at Frequency (fn).
Sometimes we are concerned with the magnitude response, for cutting performance the negative real part of the FRF
Frequency =fn
Static Compliance
Dynamic flexibility=~1/2k
Negative Real Peak
(chatter)
Magnitude Response Real part of FRF
MetalMAX Training
Manufacturing Laboratories, Inc.

24. Manufacturing Laboratories, Inc.
Why bother?
In a dynamic system component behaviors are highly interelated (e.g. everything affects everything).
Change one parameter and it is likely that the dynamic response will change, sometimes substantially.
Counter-intuitive behavior is inevitable.
Dynamic parameters, particularly damping can change.
All this will affect how much can be cut and how much the operation will vibrate (normally, resonate or chatter).
MetalMAX Training
Manufacturing Laboratories, Inc.

25. Fundamental Tool: Frequency Response Function (FRF)
(20 mm 3-fluted Tool in 30 kW 24 krpm Spindle)
Flexibility
MetalMAX Training
Manufacturing Laboratories, Inc.

26. Manufacturing Laboratories, Inc.
Basis for Analysis: The Stability Lobe Diagram
Process Damping
MetalMAX Training
Manufacturing Laboratories, Inc.

27. Manufacturing Laboratories, Inc.
5 areas of machining
Conventional Region
High-Performance Region
PoorMan Region
Blim1
Blim2 – High-Speed Machining
MetalMAX Training
Manufacturing Laboratories, Inc.

28. Manufacturing Laboratories, Inc.
5 Regions of Machining
Conventional
Typically Slow RPM with high Feed and DOC
Blim1
Light DOC where all RPM are chatter-free, but not necessarily most robust
Blim2 – High-Speed Region
“industry accepted” low DOC high feed rate finishing
All RPM are chatter –free, but not necessarily most robust
PoorMan Region
Minimal or NO Sweet Spots, almost all RPM chatter
High-Performance Region
Largest Metal Removal Rates
Must select matching RPM and DOC
MetalMAX Training
Manufacturing Laboratories, Inc.

29. Manufacturing Laboratories, Inc.
Desired Benefits
Promote Understanding
Explain Non-intuitive behavior, e.g. lobing diagram and the dynamics that produce it.
Guide user to Optimal Solution
Not necessarily looking for “precise” predictions but good guidance.
Fast Improvements
90% results with 10% of the effort.
Clearly identify limitations, eliminate………..
“finger pointing”
MetalMAX Training
Manufacturing Laboratories, Inc.

30. Manufacturing Laboratories, Inc.
What’s Needed?
Not as much as you may think.
Frequency Analyzer.
Widely available Sensors
Basic Cutting Theory
Commercial applications are becoming widely available that do not require the expertise of a “vibration expert”.
MLI’s MetalMAX™ kit with computer.
MetalMAX Training
Manufacturing Laboratories, Inc.

31. Packages for Dynamic/Chatter Prediction and Control
Measurement and Analysis
Computation and Prediction
Finite Element
Spindle Analysis and Cutting Performance Analyzer
Cutting Performance Analyzer for Machine Tools
SPATM
TXF™
Data Acquisition and Machining Analysis
PCScope
MilSimTM
Milling
simulation
Verification and Tracking
Track Data with
particular setup,
tool, machine, etc.
Audio Monitoring
of Cutting Process
Harmonizer®
CHiPSTM
MetalMAX Training
Manufacturing Laboratories, Inc.
Page 5

32. How is it typically applied
Front Line Solutions
“TXF”
Chatter free speeds and power or depth of cut levels.
“Harmonizer®”
Audio monitoring and chatter detection and correction
Existing NC Program correction.
PCScope
Generic data collection
Track balance levels and spindle vibrations, temperatures.
Off-Line Solutions
MilSim and SPA
Off-line in-depth analysis.
Good NC-Programmer tool
CHiPS
Organize and track data.
MetalMAX Training
Manufacturing Laboratories, Inc.

33. Two Basic Approaches: “Trial and Error” and Predictive
Similar to how we do it now in that we take test parts or run test work pieces and change things based on experience.
Additionally, we can integrate cutting theory and signal analysis to direct the changes more efficiently.
Predictive
Measure dynamics of tooling before cutting then compute behavior.
Simulate cutting and establish maximum parameters.
Verify results when implemented and have the ability to correct for subtle changes that may occur.
MetalMAX Training
Manufacturing Laboratories, Inc.

34. Predictive Approach. How do we do this?
Easiest way is called “impact” testing or modal analysis.
Use a hammer to excite the tool over a wide frequency range and and an accelerometer to measure the response and create an FRF (Frequency Response Function).
With proper software and setup measurement takes less than 5-minutes per tool.
MetalMAX Training
Manufacturing Laboratories, Inc.

35. Advantages and Disadvantages of Predictive Approach
Fast with minimal machine down
time.
No requirement to run machine.
Flexibility to determine
performance for all operation conditions.
Quick check for changes after “events”.
Disadvantages:
Limited accuracy depending on inputs.
Some technique and equipment needed
MetalMAX Training
Manufacturing Laboratories, Inc.

36. Manufacturing Laboratories, Inc.
What is our concern.
Obviously the tool-work piece interface.
The flexibility and frequency behavior on the tool and on the part at the location of the cutting interface.
The entire machine and all its components contribute to this behavior but we are only concerned with how it is affecting just “ONE” location: Where cutting occurs (the cut interface).
We are only concerned with displacement for a given force, or the flexibility.
MetalMAX Training
Manufacturing Laboratories, Inc.

37. FRF Measurement with MetalMAX™ Equipment4 3 2 1
EXCITATION
(HAMMER)
RESPONSE
(ACCEL)
Sensor Interface Module PC
Accelerometer
STRIKE
Hammer
Power Cable
Sensor Cable
Schematic of Measurement Setup
for TXF “Tap” or “Ping” test.
Actual MetalMAX™ Equipment
MetalMAX Training
Manufacturing Laboratories, Inc.

38. Frequency Response Function to Cutting Performance (Analytical Solution, TXF)
Chatter in red areas
MRR Axis
Chatter freqs. (in red) and resonant speeds
Lobing Diagrams
Provide MRR (Depth of Cut) and
Spindle Speed values
Measured Frequency Response Function (FRF)
MetalMAX Training
Manufacturing Laboratories, Inc.

39. Manufacturing Laboratories, Inc.
General FRF Procedure
A FRF quantifies a tool’s “flexibility” frequency by frequency.
Excite system
Measure force
Measure response
Transform into frequency domain (Fourier Transform)
divide frequency by frequency
See video demonstration.
(PLUCKING A TUNING FORK)
MetalMAX Training
Manufacturing Laboratories, Inc.

40. Cutting Performance (TXF)
Max Torque
Max Power
Stability Lobes
Power Lobes
MetalMAX Training
Manufacturing Laboratories, Inc.

41. Advantages and Disadvantages of Trial and Error Approach
Most Accurate
Easy
Low skill level required
Software/hardware aids are
commercially available, vibration meters,
audio detectors, etc.
Disadvantages:
Time consuming
Consumes work piece material and tools and machine time.
MetalMAX Training
Manufacturing Laboratories, Inc.

42. Maximizing MRR with Width of Cut Increases
Harmonized
> 475% increase in Power and MRR
Spindle Speed: 16,580 RPM
Axial Depth of Cut 25 mm
Radial width of cut 1.8 mm
Cut Power 1.75 kW
GREAT SURFACE!!!
Spindle Speed: 20,000 RPM
Axial Depth of Cut 25 mm
Radial width of cut 0.25 mm
Cut Power 0.3 kW
BAD SURFACE
MetalMAX Training
Manufacturing Laboratories, Inc.

43. Manufacturing Laboratories, Inc.
Knowledge of the spindle speed is essential.
Spindle speed components generally dominate the audio spectrum unless chatter is very severe.
Other audio sources are related to spindle speed, bearing passing frequencies, air-oil hiss, etc.
Correct setting of threshold maximizes sensitivity.
Unfiltered
Filtered
MetalMAX Training
Manufacturing Laboratories, Inc.

44. Trial and Error Example
10,000 RPM
8393 RPM
Corner Cut, 10 mm deep, 12 mm wide
MetalMAX Training
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45. Trial and Error Example
10,000 RPM
Frequency Content with no filters.
8393 RPM
Frequency content no filters.
MetalMAX Training
Manufacturing Laboratories, Inc.

46. Manufacturing Laboratories, Inc.
Milling Simulation
Simulation package needs measured dynamics as input.
Rapid more accurate solutions to speeds, depths of cut, feeds, cutting forces, tool deflection and surface error.
Include tooth run-out, imbalance, non-uniform pitch.
Excellent front-line, solution for process engineers and NC programmers.
MetalMAX Training
Manufacturing Laboratories, Inc.

47. Manufacturing Laboratories, Inc.
Most Important: Cutting Tool Tracking and Control The CHiPS(TM) Database
To get the maximum payback each cutting tool assembly must be uniquely identified.
Machine, spindle, holder, cutter, manufacturer’s, stick out length’s, etc. must be tracked by either the customer tool management system or our customized Microsoft Access database for tool setup tracking with dynamics (CHiPS).
Record optimum speeds, feeds and depths of cut.
Based on measurement and calculation (TXF, MilSim™, etc.) and verified by cutting tests (Harmonizer).
Emphasize slotting information (the least stable case).
Data will not change unless a different tool, machine tool, or spindle is used. In fact results for identical model machines and spindles can be used on all machines of that model and spindle type.
Control of tool set up is required to insure database speeds, feeds, and DOC’s are valid (Dynamic repeatability and consistency).
MetalMAX Training
Manufacturing Laboratories, Inc.

48. CHiPS: Tracking all Tooling information
MetalMAX Training
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49. Manufacturing Laboratories, Inc.
Is this Technology new?
No!, only in the way it is being applied.
Vibration measurement is very well developed.
Basic machining dynamic theory well-known for decades by academics and large corporate MR&D departments.
The process or practice is the focus rather than its affects.
Detect what is happening in the cut, not at the bearings, the motor, under the work piece, etc.
“Modal” Analysis or Frequency Analysis has been utilized extensively with the advent of the digital computer and algorithms.
Mostly in the design and product test areas.
To determine and measure resonance's (aircraft, autos, disk drives, etc.).
Even in the design of machine tools and components.
Spindle Rotor Analysis
Damping of fixtures
MetalMAX Training
Manufacturing Laboratories, Inc.

50. Is this all worth it? The Good News: YES!
PREDICTABLE and CONSISTENT: Well controlled setups will behave consistently.
Identical model machines even of different age will show minimal variation in frequency.
Stiffness will not change significantly over time.
Damping may change somewhat but its affects can be avoided.
PERFORMANCE IMPROVEMENTS: Stable cutting horsepower can generally be increased % or more compared to practically applied techniques.
COST AVOIDANCE: Tool life, time between spindle rebuilds, longevity of the machine, rotary table life, any machine component wear can generally see substantial (> 50%) improvements.
MetalMAX Training
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51. Other Benefits of Easy Dynamic Measurement
Rapid dynamic measurement can quickly identify many conditions.
Non-intuitive behavior.
Most flexible mode may not be the most likely to chatter.
Quickly identify which component is producing the most flexible mode.
Identify when stiffness or damping is loss.
Quickly detect changes or compare performance.
MetalMAX Training
Manufacturing Laboratories, Inc.

52. Automotive Part Example: Mild Steel Tubing
1. Starting Point: Company, Tooling Company, and Machine Tool company spent 15 months designing process – POOR TOOL LIFE 2 1
2. Ending Point: DATA driven Stability Diagram provided MAP to change RPM
MetalMAX Training
Manufacturing Laboratories, Inc.

53. Automotive Part Example: Mild Steel Tubing
Shop chose:
24,000 rpm
3mm ADOC
10,000 mm/min
0.208 mm/tooth
Tool Life 20 pcs
Endmill Cost: $200
45 second cycle time
Changed Parameters
15,500rpm
6,000 mm/min
0.193 mm/tooth
Tool Life 80 pcs
Endmill Cost: $65
53 second cycle time
Not constraint machine
Improved Cost: ($10/part – $0.81/part) = $9.19/part
Yearly Savings: $9.19/part * 700 parts/day * 250 days/year = $1.6 million
MetalMAX Training
Manufacturing Laboratories, Inc.

54. Manufacturing Laboratories, Inc.
Story 2: Outsourcing
8000 rpm
0.375” ADOC
Same Tool, Same Toolholder, Same Stickout
Different machines have Different Stability Diagram 1
MetalMAX Training
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55. Die Shop Example: Cast Iron
1. Starting Point: Machinist chose DOC based on CAM software and past practice – HEAVY CHATTER 1 2
2. Ending Point: DATA driven Stability Diagram provided MAP to change RPM
MetalMAX Training
Manufacturing Laboratories, Inc.

56. Die Shop Example: Cast Iron
Die shop chose:
1146 rpm
0.125” ADOC
23 ipm
(0.005 ipt)
Chatter
Changed Parameters
2120 rpm
0.040” ADOC
84 ipm
(0.010 ipt)
No chatter
MRR = 1.5* * 23 = 4.31 in3/min
MRR = 1.5 * 0.04 * 84 = 5.04 in3/min
Improved Performance: ( )/4.31 = 17%
Cost Savings: $175/week ($100 inserts + 1 hour/week time * $75/hour)
$8750 savings/year + Reduced spindle wear and tear + improved quality
MetalMAX Training
Manufacturing Laboratories, Inc.

57. Cutting Parameter Selection
Comparison of how are speeds, feeds and depths of cut chosen?
The Conventional Approach
Empirical/Experimental Guidelines
Highly Experienced Planner.
Technological database from cutting tool supplier.
Operational limits from machine tool supplier.
Turn Key applications.
Note: The guidelines are subjectively applied depending on the situation.
Program and Make Parts
Determine Acceptability
Accept or Modify
A Process Based Approach
(Strategy 2)
Measure the dynamics.
Define Dynamic Condition at cutting interface.
Compute optimum cutting parameters and compare to other operational guidelines.
Program and make part.
Monitor results.
Poor material removal rates (speed, feed, DOC
Scrapped Parts
Excessive “benching”
Power tool life and tool failures
Accelerated spindle wear
Poor process reliability
Unpredictability
Inferior quality
All of this results in wasted time and money
Monitor
Results
Make
Part
Measure
Setups
Compute
parameters
Operational
Guidelines
Program
with empirical
guidelines
Make Part
Determine
acceptability
Modify
Yes No
MetalMAX Training
Manufacturing Laboratories, Inc.

58. Resource Investment: Conventional vs Process based (MetalMAX)
Resources Expended:
Conventional
MetalMAX
MetalMAX Training
Manufacturing Laboratories, Inc.

59. Implementation Strategy #1: Eliminating Chatter
TXF
OFF-LINE (new cutter or new program): Use hammer kit and TXF software to develop “Stability Charts” for problematic cutters.
In-Process (current chatter condition with pre-existing NC program). Use microphone and Harmonizer software to monitor chatter signal and suggest new speeds and feeds.
Record results in tooling database or CHiPS database program for future reference.
Periodically monitor high volume jobs using Harmonizer to insure chatter is not present.
Torque Limit
Unstable
Stable
Speeds
Harmonizer
Chatter
all
MetalMAX Training
Manufacturing Laboratories, Inc.

60. Implementation Strategy 2: Maximizing Machine and Cutter Performance
Identify 20% of tooling that performs 80% of metal removal or consumes 80% of machining time.
Use MetalMAX hammer kit and TXF program to create stability charts (maps) for each cutter.
Perform cutting tests on a few selected cutters using microphone and Harmonizer to validate predictions and to calibrate results on all cutters.
Record data in CHIPS database.
Make information accessible to NC programmers.
Have machinists monitor and provide feedback periodically regarding performance. Use Harmonizer for periodic monitoring, fine tune when necessary, update database and re-measure as needed (generally not required).
Highest Power Stable Region with little chance to chatter.
MetalMAX Training
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61. Manufacturing Laboratories, Inc.
Implementation Strategy 3: Matching tooling to machine (and tool tuning).
Identify possibly redundant tooling systems, e.g. multiple length cutter configurations, multiple flute, cutters used across machine platforms, etc.
Measure redundant tooling systems across machine tools using TXF.
Review “stability chart” results.
Identify those cutters with superior cutting performance in a given machine and machines-cutting tool combinations with superior cutting performance.
Will result in dramatic reduction in required setups and provide preferred machine-tooling configurations (e.g. better identify roughers, finishers, face millers, end millers, 2 flute machines, 3 flute machines, etc.)
Alternatively, multiple length cutters of a given size can be measured to identify which length provides the optimal cutting performance (e.g. shorter not always better, see right)
Shorter
Cutter
Longer
Cutter
Larger deeper
Stable pocket,
(shorter cutter
not needed).
MetalMAX Training
Manufacturing Laboratories, Inc.

62. Implementation Strategy 4: New Equipment Qualification
Similar to matching machine to tooling strategy except current measurements will afford the analyst benchmark results for popular shop setups to be compared against “test” cutters or alternative OEM designs without having to run cutting tests.
These setups can be quickly compared with any new setups considered for the shop through a quick TXF hammer test.
Additionally, the shop’s current stackups may be taken and measured on potential new machines to see what stability performance improvement may be expected on the new machines.
Benchmarked cutter
Test Cutter
Performance at
Least 2X
MetalMAX Training
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63. Implementation Strategy 5: Part-Try-Out (PTO) Optimization
Tooling should already have been qualified and measured with prior strategies.
Work piece and fixturing can now be added at selected machining states with TXF.
Milling Simulation MILSIM package can be used concurrently with programming to optimize feed rates based on bending moment limits, cutting force and dynamic cutting accuracy.
Harmonizer should be used to provide feed back for next
MetalMAX Training
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64. Implementation Strategy 6: Predictive and Preventive Maintenance.
Establish a measurement artifact for each spindle interface in the shop (e.g. HSK, ISO, etc.).
Dimensions of artifact should be approximately a 1 L/D with a diameter approximately equal to the gage length.
With machine in known “good” condition make TXF measurement, store, and during routine maintenance checks re-measure artifact and compare (reduction of damping or loss of stiffness will precede typical spindle wear or de-commissioning signals by at least 3 months).
After spindle or machine crashes or extraordinary events spindle dynamic condition can be check.
Dynamic performance and hence proper refurbishing or replacement of machine components, particularly spindle can be verified.
Dynamic consistency of machine can be established.
Spindle In
Good
Condition
Spindle In
Bad
Condition
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65. Summary of Implementation Issues
Exploiting Dynamic Consistency
By controlling our tool setups and measuring the dynamics the optimal operating conditions can be repeatably targeted with corresponding benefits.
High production rates can be reached as well as high machine utilization.
Improve control of cutting processes
Apparent random vibration behavior can be controlled by implementing a means to define a previously unknown critical characteristic of the machine setup.
Better more consistent part quality is achieved.
Maintenance improved
The control of vibrations dramatically reduces machine and tool wear thereby reducing maintenance and repair costs.
Quality control is improved as machines that are near design life of more easily identified.
MetalMAX Training
Manufacturing Laboratories, Inc.

66. Manufacturing Laboratories, Inc.
Summary
Dynamic analysis can be applied easily and in a “Shop Floor Friendly Fashion”.
Both for trial and error approaches and predictive analytical approaches.
Cost and down time is minimal.
It can provide objective and clear understanding as to the dynamic affects driving cutting performance.
Benefits include both performance enhancement and “cost-avoidance”.
It is an excellent compliment to other machining systems for tool wear, cutting accuracy (machine metrology), etc.
MetalMAX Training
Manufacturing Laboratories, Inc.

67. Manufacturing Laboratories, Inc.
Downstream Benefits
Proper implementation of HP-HS techniques will lead to:
Elimination of adverse vibrations
Reduction of catastrophic wear on machine and tools thereby lowering maintenance costs and consumables
Expanded flexibility in types of parts and manufacturing processes.
Improved quality and more predictable processes leading to better cost estimation.
MetalMAX Training
Manufacturing Laboratories, Inc.

68. Manufacturing Laboratories, Inc.
Overall Benefits
Deal with chatter problems effectively and quickly.
Minimal or elimination of down time due to chatter problems.
Minimize part damage and scrap/rework.
Extend machine and tooling capabilities.
Fewer tools needed to machine same features.
Reduce tool fatigue failures and extend tool life.
Add flexibility to part programming strategies.
Objectively deal with the natural limitations imposed due to machine and tool dynamics.
Eliminate “Finger-Pointing”
Accurately compare machines or tool stack-ups.
Select the best machine and/or tool setup for a particular application.
MetalMAX Training
Manufacturing Laboratories, Inc.

69. Limitations of Approach
Critically dependent on cutting stiffness and process damping wavelength.
Once established for a particular grind of tool and material then will produce accurate predictability.
Will change after tool wears (usually increase stable limits).
FRF measurement of 1/4” diameter tool is practical lower limit of effective measurement.
Improvements currently being developed
In worse case an indirect measurement approach can be applied.
Measurement of dynamics performed under static conditions.
Measurements can be made at speed with non-contact sensor.
A few advance and current spindle designs have poor dyna repeatability and consistency.
MetalMAX Training
Manufacturing Laboratories, Inc.