Improving high-speed machining material removal rates by rapid dynamic analysis

Stability prediction and chatter avoidance in high-speed machining requires knowledge of the tool point dynamics. In this paper, three advances toward the rapid identification of the tool point frequency response and correspo nding stable cutting parameters are described: 1) stable speeds determinati on using non-contact periodic impulsive excitation of the tool point (produ ced by spindle rotation and a stationary magnet) in conjunction with once-p er-revolution sampling, 2) Receptance Coupling Substructure Analysis for th e analytic prediction of the tool point response, and 3) once-per-revolutio n sampling of the audio signal during cutting to determine stability behavi or.