Introduction to Machining Dynamics
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The reason dynamics has not brought machining to a complete standstill is that there are stable zones that can be found without frequency measurements, trial & error or luck, although they will have metal removal rates that are 5-10X less than optimal. They are:
- Speeds so slow that the tool deflects, rebounds and settles down before the next tooth enters the workpiece.
- Cuts so shallow that not enough force is generated to move the tool.
Is this where you are running now?
TAKEAWAYS:
- As you can imagine, every milling cutter/toolholder/spindle/machining center combination has a different frequency. Well, how many can there be? Try 60 Billion. We counted.
- With so many potential combinations, there is no paper chart, sliding calculator or CAM software program that can predict what a particular milling tool will do in a specific machine, spindle and toolholder without measuring its frequency at the tool tip.
- There is no out-of-box solution to chatter. There is no such thing as a chatter-free endmill . vibration-free toolholder or most stable interface. They only change where the tool will chatter, not if.
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BlueSwarf MetalMax™ technology and Tool Dashboards™ measures the frequencies (by hitting with a real expensive hammer) and calculates the maximum possible stable speeds, feeds and cutting depths for your milling operations.
