Productive Machines, a spin out from the University of Sheffield Advanced Manufacturing Research Centre (AMRC) has introduced its Essential Optimization — a web application that prevents chatter vibrations and offers engineers a simple-to-use solution to select stable spindle speeds and feed rates.

The Essential Optimization app, powered by Productive Machines’ machining dynamics algorithms, promises to improve machining operations by mitigating chatter vibrations and cutting forces related problems. This new capability enables manufacturers to increase productivity, reduce waste and improve surface finish. It also reportedly provides a brand-new approach to stable milling by taking into account both the machine tool dynamics and the cutting forces involved ahead of manufacture. This user-friendly software-as-a-service (SaaS) is expected to assist manufacturers in making their processes more efficient without installed software or machining physics expertise.

Source: Productive Machines

Additionally, the Productive Machines’ Spindle Speed Calculator, which is part of the Essential Optimization app, relies on Frequency Response Function (FRF) obtained via tap testing, which is a technique used to identify the structural dynamics of the machine tool assembly.

The Spindle Speed calculator uses FRF data to generate a Stability Lobe, which is a visual representation to determine the stable regions. This tool guides engineers in making informed decisions, ensuring a chatter-free milling process. Key benefits of using the Essential Optimization app include:

• Increased productivity: By reducing cycle times and lead times to achieve more cost-effective machining operations.
• Sustainable manufacturing: By eliminating iterations and expensive prove-outs on machine tools that waste time, energy and materials.
• Minimal tooling costs: By mitigating chatter vibrations to minimize tool wear and save on tooling costs.
• Quality assurance: By producing parts with optimal surface finish and dimensional accuracy.
• Integration with feed rate calculator: Users can effortlessly input chatter-free spindle speed and depth of cut values obtained from the Spindle Speed Calculator into the Feed Rate Calculator. This seamless integration optimizes feed rates by considering cutting forces, resulting in optimal machining performance.

For more information, visit the Productive Machines’ website.