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.