Advanced Technologies for Discrete-Parts Manufacturing

Significant advances have been made in machining technology, most notably machining centers capable of spindle speeds and feedrates that are an order of magnitude higher than conventional. However, the use of this new technology requires much more technical expertise, and experience and intuition are no longer sufficient. Specifically, machine tool productivity can be greatly enhanced if information related to machine tool dynamics can be measured and presented to the user in a way that facilitates intelligent selection of the cutting conditions. Chatter in machine tools is cause by inadequate information about the process limitations imposed by machine tool dynamics. Although chatter is a phenomenon for which a solution is well-known in academia, it is still the most problematic condition experienced in machining operations. Through this research project, Manufacturing Laboratories, Inc. (MLI) will create a new Machine Tool Integrated Multisensor Chatter Detection and Avoidance System (MICA) to address exactly this problem. There is a distinct need to transition the existing technologies available for chatter detection from a user-intensive process to an automatic process integrated into existing machine tools. MICA will provide real-time data to the machine controller allowing adjustment of the machining parameters, avoiding chatter. MICA will build on MLI’s patented Harmonizer, by (1) extending its functionality to include the ability to accept signals from multiple sensors, extending its diagnosis capability to lower frequency ranges, (2) providing a machine-integrated solution instead of a handheld manual device (3) identifying methodologies to adapt the chatter recognition theory to include specialty cutters. We have already identified this need within the market and have made strategic agreements with two leading machine tool suppliers, who will provide additional support for this research.