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MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-1 Operating the Harmonizer.

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Presentation on theme: "MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-1 Operating the Harmonizer."— Presentation transcript:

1 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-1 Operating the Harmonizer

2 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-2 General Procedure  Record background noise with machine operating at some high spindle speed.  Determine a threshold.  Record machining operation.  Analyze for chatter.  When chatter occurs, change speed and feed rate (constant chip load) per suggested values.  Execute new machining operation and record results.  Chatter?  Yes, then repeat with new speed and feed values.  No, then adjust feed rate with limits of machine, spindle, holder and cutting tool.  Alternatively, can attempt to go deeper.

3 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-3 Basic Steps  Hook-up microphone and make sure it is turned on.  Enter: Maximum permissible speed (1); Commanded spindle speed (2); Number of cutting edges (3).  Run machine at idle no cutting.  Record Sample (4).  Use “Fine Tune” (5) to determine spindle speed.  Set threshold, estimate (6) or manually (7).  Record cutting signal (4).  Fine Tune (5) again to detect any speed changes.  If chatter indicated (8), click on Analyze button (9).  Repeat as necessary. 12345689 7

4 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-4 Detection of Chatter (Analyze Button)  Lists:  Starting Speed;  Suggested Spindle Speed (Harmonizer Spindle Speed);  Detected Chatter Frequencies.

5 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-5 Ready for Next Cut  Suggested “Harmonized” spindle speed and feed rate (constant chip load) are entered automatically for next cut.  Repeat procedure by recording new cut to determine if chatter is eliminated.

6 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-6 Next Cut Results  If cut is now stable, then done or can adjust feed up or down with no danger of chatter.  Alternatively can try deeper cut.  If cut is unstable can continue doing analysis, making suggested speed changes until stable or Harmonizer reports that no spindle speed is available.

7 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-7 Two Main Screens (F1 and F2)  Plot Screen  Main screen with time and frequency plots.  Activated by Hot Key (F1)  History Screen  Provides detailed history of recorded cuts.  Hot Key (F2)

8 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-8 Detailed Setup/Display (F3) 7 Setup/Display Options  F1: Main screen with frequency and time displays.  F2: History of spindle speed adjustments.  F3: Project description settings.  F4: Cutting parameters.  F5: Chatter Detection parameters.  F6: Preferences, data directories.  F7: Recording Preferences.

9 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-9 SETUP: Cutting Parameters (F4)  Defines Cut.  Necessary parameters number of teeth and spindle speed accessible on front screen.  Other parameters optional and mostly for documentation purposes.  Material selection necessary for process damping.

10 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-10 SETUP: Chatter Detection (F5)  Chatter Detection Refinements.  Critical parameters shown on right side menu.  Other parameters refine settings.  Target speed ranges limit set by “lobe size”.  Highest lobe determines number of potential available speed ranges.  Chatter frequency range focuses detection frequencies.  Spindle speed filter width for harmonic filter set in terms of speed range.  Can eliminate specific unwanted frequencies with background filters.

11 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-11 SETUP: Chatter Detection (cont.)  Machine Limits  Only maximum speed is critical and can be set by spindle speed range as well as maximum surface velocity.

12 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-12 SETUP: Preferences (F6) File locations, units and language.

13 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-13 SETUP: Recording Preferences (F7).  Set data collection source and sample times.  Mostly use microphone but can use accelerometers.  Default minimum sample is 2 seconds. Can record up to 600 seconds.  Can do continuous recording but must set sampling window to none or rectangular in F5 chatter detection specs.  Direct access to Windows Multimedia properties window to set recording levels.  Our example again from start to finish.

14 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-14 Recording Background  Setup parameters:  maximum allowable speed;  commanded Speed;  number of cutting edges.  Operate spindle at desired speed and record.  Use fine tune to more precisely determine spindle speed and adjust filters.  Can set threshold two ways.  Manually adjust making sure that chatter indicator stays off.  Use computer’s “Estimate” function to set threshold (sometimes very conservative)

15 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-15 Record Cut  If chatter present, user will see red chatter indicator.  For long recording times, may need to adjust FFT window.  Fine tune of spindle speed may be necessary on heavy cuts where speed may change.  If chatter detected use Analyze button.

16 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-16 Analyze  A spindle speed and feed will be suggested.  New speed will be automatically updated on main screen for next sample.  New feed recommendation based on chip load input on cutting parameters setup screen (F4).  Detected chatter frequencies will also be shown and recorded on history screen (F2).

17 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-17 Run and Record New Cut  If new cut is not stable repeat Analyze step.  Otherwise you are done (stable) and can adjust feed rate based on other limitations (tool limits, spindle bending moment, chip evacuation, etc.), or go deeper.  Can now check for resonance.

18 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-18 Resonance Check  Turn off Harmonic Filters.  If “suspected “ resonance is present it will be indicated and the analyze function can suggest a minor speed change range.  Markers indicate:  once per revolution;  tooth frequency;  and harmonics. Note: Absolute detection of resonance not possible without measurement of dynamics, just an indication.

19 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-19 Resonance Analysis  Suggests slight reduction in speed.  Provides values for tooth passing and largest harmonic frequencies.  Additionally supplies ratios to indicate size of suspected resonance and harmonic number of spindle rotation value.

20 MetalMAX TrainingManufacturing Laboratories, Inc.Harmonizer-20 Reselecting Speed  Can use back button to reselect spindle speed.  Can reset any preference or setting, usually maximum speed to permit reselection of alternative spindle speed.  Can select any maximum speed, even below current spindle speed.

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