SBIR Phase I: Chatter Avoidance Software for High Speed Milling

9861180小企业创新研究（SBIR）第一阶段项目将探索复杂颤振理论在高速加工过程操作员控制中的应用。该方法将是数控（NC）程序验证软件，提醒机械师使用他们选择的速度和进给可能发生的振动问题，并推荐替代的优化速度。在高速铣削“刀具调谐”方法的背景下，评估和限定现有颤振理论的误差；[2]通过精确测量和表征振动，在最先进的高速铣削设备上确认理论结果；和[3]将这些结果整合到一个NC程序验证软件包中，该软件包提供(a)根据相关工具预测的理论稳定叶片推荐的最佳主轴速度，(b)向机械师传达零件和零件程序中可能出现严重颤振的地方的简单方法，以及(c)用户根据经验修改参数的方法。高速磨机运营商不太可能意识到他们的磨机性能的全部优势，而是依赖于保守的车间实践，这是基于传统磨机和颤振避免策略。该软件有望指导车间人员通过最佳的无抖动速度和饲料选择过程，尽管基于复杂的理论，但它将使用他们熟悉的术语。

9861180 This Small Business Innovation Research (SBIR) Phase I project will explore an application of complex chatter theory to operator control of high-speed machining processes. The approach will be numerical control (NC) program verification software that alerts machinists to vibration problems that might occur using the speeds and feeds they have selected and to recommend alternate, optimized speeds. Phase I will: [1] Evaluate and bound the errors of existing chatter theory in the context of a "tool tuning" methodology for high-speed milling; [2] Confirm theoretical results at a state-of-the-art high-speed milling facility by measuring and characterizing vibrations accurately; and [3] Consolidate these results within an NC program verification software package that provides (a) recommended optimal spindle speeds, based on the theoretical stability lobes predicted for an associated tool, (b) a simple means to convey to a machinist where on the part and in the part program serious chatter is likely to arise, and (c) a means for users to amend parameters based on experience . High-speed mill operators are not likely realizing the full advantage of their mill performance capabilities, relying instead on conservative shop practice, which is based on conventional mills and a chatter avoidance strategy. This software is expected to guide shop floor personnel through an optimal chatter-free speed and feed selection process, and though based on complex theory, it will use terms familiar to them.