SBIR Phase II: Chatter Avoidance Software for High Speed Milling

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This Small Business Innovation Research (SBIR) Phase II project will integrate a novel, inexpensive device to measure tool dynamics with a general purpose analysis program that will optimize the use of high speed machining centers as a routine shop floor practice. High speed machining is often limited by chatter conditions. These conditions depend on system dynamics and cutting conditions. The product to be developed will provide an integrated hardware/software solution to assist users in selecting optimal spindle speeds and tool depths without the intervention of experts or specialized equipment. The product will handle general tool geometries, tool paths and in-process part geometries working in conjunction with an industrial grade NC verification program. The program will specifically provide recommendations under low tool immersion (light cut) conditions that are commonly used to avoid tool wear in hard materials. Novel aspects include: (1) the study of chatter under transient conditions; (2) sculptured surface parts; (3) a new analytical solution that provides important physical insights under low tool immersion conditions; (4) a new simulation model that is not restricted to uni-directional feed; and (5) the extension of a new measurement device to provide full tool dynamic data.