New AI-Powered Automated Tap-Testing Software
New RCSA Predictive Milling and Virtual Design Suite
Designed for Process Planners, Turnkey Builders and Milling Tool Designers. Build virtual models of milling tool and toolholder assemblies and generate Dashboards with accurate performance predictions for a specific machine tool and spindle. Uses RCSA artifact measurement to capture unique and dynamic spindle frequency profile. Enables VirtualRunoff™ of multiple configurations, including specials, before purchase. Unlimited Dashboards.
The objective of this project is to enable pre-process milling parameter selection for “first part correct” production. This will replace the current practice of trial-and-error part path validation and will be achieved by predicting the tool point frequency response function using automated tap-testing or the RCSA algorithm. Given the tool point response, frequency-domain algorithms for stability and surface location error can be applied to separate feasible and infeasible zones within the spindle speed-axial depth of cut domain. Once acceptable spindle speed-axial depth of cut combinations are determined, they will be presented in a new user-friendly format, the Tool Dashboard, similar to an automotive dashboard display. The intended customer for this project is any user of computer numerically-controlled (CNC) machining technology. This work is a collaboration with the University of North Carolina at Charlotte and Manufacturing Laboratories, Inc.
Two Areas of Research and Development
AI-Powered Automated Tap-Testing
Measuring the tool point frequency with a tap-test and the resulting stability lobe diagram is the global standard for milling optimization and chatter avoidance. It is in use by top tier manufacturers and leading research organizations worldwide. However, its cost and complexity have prevented its widespread deployment . We have developed new software that automates the analysis process. It requires no extensive training on chatter theory or mechanical vibrations and no waiting for results. The user conducts the simple tap-test and instantly receives an interactive visualization of the stability lobe diagram, the Tool Dashboard. The subscription-based software is compatible with tap-testing kits and modal testing instruments from several manufacturers.
RCSA - Virtual Milling