Hopefully, we have convinced you of the importance of the science of Machining Dynamics, that is understanding the behavior of the tool point during milling. Tools are not 100% rigid, they deflect when a tooth enters the cut and snap back when it exits. The machine, the spindle, the toolholder and the cutter are a unique system that vibrates at a unique frequency. Cutting forces and speeds can be tuned to avoid chatter and optimize performance.
Now, how do we apply this? To generate a stability lobe diagram, we attach an accelerometer to the tool tip of an assembly in a spindle. We tap it with an instrumented hammer to measure it's flexibility and damping properties. Software analyzes this data and generates a stability lobe diagram. Kits are commercially available and new software makes this a fast and easy process.
There is something new on the horizon. We can tap an artifact one time in a machine and then model any toolholder and cutter combination to accurately predict it's tool point behavior and generate a stability lobe diagram without any additional tap-tests. We will need the help of machine tool builders and tooling manufacturers to bring this fruition.
Sharing information about high performance milling technologies, the result of 30 years of research.