Does de Smart Spindle Unit offer reliable results in terms of stability and

production?
The main objective pursued in the report is to address and mitigate vibration instabilities
in milling processes through the use of active structural control techniques. Chatter
refers to unwanted vibration or instability that can occur during machining operations,
particularly milling, and can negatively affect surface finish, tool life, and overall
machining performance. It also aims to research and develop active control strategies
that can effectively suppress vibrations in grinding processes. Through the active
control of the structural dynamics of the milling system, such as the use of sensors,
actuators and control algorithms, the researchers seek to minimize or eliminate the
occurrence of vibrations and improve the stability of the machining process and also the
article explores the feasibility and effectiveness of active structural control techniques to
mitigate vibration instabilities in milling operations, with the ultimate goal of improving
productivity, surface quality, and tool life in machining processes.

What is the factor Maximum metal remove rate (MMRR)?

The maximum metal removal rate (MMRR) is a numerical indicator that evaluates the
production capacity of a machine tool. However, the MMRR is restricted by different
factors, including the onset of instability during machining, which is related to the
vibration modes of both the machine and the tool. By modifying the dynamic
characteristics in this way, it is possible to reduce instabilities and improve the
maximum metal removal rate (MMRR). This can be accomplished through physical
modifications, such as redesigning or modifying the structure of the machine. However,
there is an alternative that consists of using an active control system to alter the
dynamics of the system. In an active control system, actuators, sensors, computers, and
software are used to replace or supplement mechanical components, allowing the
system to exhibit the desired dynamic response characteristics.

How does the Maximum metal remove rate is use as a measure for the
productivity?
Using the maximum metal removal rate as a measure of productivity allows for an
assessment of how efficiently and quickly material is being removed during milling. A
higher maximum metal removal rate indicates a higher productivity level, as it signifies
that a larger volume of material is being removed in a specific time period, leading to
faster completion of machining tasks. Discusses the use of maximum metal removal rate
as a quantitative measure of productivity and can explore techniques, such as active
structural control, to mitigate vibration instabilities and improve maximum metal
removal rate in milling operations.
How the Smart Spindle Unit work?
The Smart Spindle Unit (SSU) is made up of several elements, including the spindle,
tool holder, cartridge, actuator, part of the telemetry system, and its housing. The
objective of the SSU is to improve the production capacity of a milling machine through
active vibration control.
Does de Smart Spindle Unit offer reliable results in terms of stability and
production?
The design of the Smart Spindle Unit (SSU) is based on the hard design in the use of numerical
data. Initial experimental analysis of the SSU shows that the system dynamics were neither
controllable nor observable.Frequency response functions (FRF) were measured between the
voltage inputs to the power amplifiers and the voltage responses of the tool at stationary
coordinates. The initial detected were performed with the spindle at rest (0 rpm). Figure 1 is a
diagram of the Maximum Singular Values (MSV) of these FRFs. The MSVs give a limit to the
FRF response of the system. From the MSV the modes of the system can be identified.The first
tool mode occurred at approximately 800 Hz, however, as shown in this figure, it had little part
in the response. Therefore, a model state space derived from the measured FRFs would not be
controllable and observable.The reason why the system was neither controllable nor observable
was due to an anti-resonance in the FRF between the actuators and voltage sensors. The anti-
resonance frequency occurred at virtually the same frequency as the fundamental mode of the
tool. the anti-resonance was by modal cancellation between the rigid body modes of the
cartridge/spindle system.
Controllability and observability could have been achieved by changing the resonance
frequencies of the cartridge and spindle to frequencies above the fundamental frequency of the
tool; however, to do this would have required a complete redesign of the SSU, and such
modifications were beyond the available budget and time.

Wich were the conclusions of the Sandia Laboratories?

This project demonstrated that structural control can be used to increase the maximum
metal removal rate of a grinding machine by more than one order of magnitude. Although
these results are very promising, there are still practical limitations to this technology.The
design of machines that can correctly take advantage of the use of active control is an
evolving area of study. These machines must be designed to allow full observability and
controllability of the vibration modes of interest. For this effort, the tool was modified to
overcome this issue, however, on a more mature system, this type of alteration would not be
acceptable.Because actuation and detection occurred in two separate coordinate systems,
one rotating and the other stationary, the control system was unnecessarily complex.Active
control changes the dynamics of the machine in such a way that chatter instability occurs at
much greater depths of cut. Currently, this requires the intervention of an operator.
However, theoretically, the machine could be given enough intelligence to make these
changes on its own.