Dynamics Measurement Kit for Chatter-Free Machining
The Challenge
Many machining companies struggle with unstable cutting conditions such as chatter, leading to poor surface quality, reduced tool life, and machine wear. Operators often rely on trial-and-error or conservative parameters, which limits productivity. Standard tooling recommendations do not always reflect real machine behavior. Each machine-tool combination behaves differently, making it difficult to consistently achieve optimal performance. This results in lost time, higher costs, and inefficient machining processes.
What This Demonstrator Does
This demonstrator uses a tap test (impact test) to measure the dynamic behavior of a machine-tool setup. It consists of an impact hammer, accelerometer, and signal analyzer that capture vibration data directly at the tool tip.
The system calculates the frequency response function (FRF) and generates stability lobe diagrams, helping identify optimal cutting parameters. The solution is designed to be shopfloor-friendly, with simplified analysis and visual outputs.
What You Gain
- Reduced chatter and improved surface quality
- Increased tool life and reduced tool costs
- Faster process setup and less trial-and-error
- Higher productivity through optimized cutting parameters
- Better understanding of machine behavior
Who Is This For?
This demonstrator is ideal for machining SMEs using CNC milling machines that experience vibration or instability issues. It is particularly useful for companies working with varying setups (different tools, holders, or materials) and looking to improve process reliability.
It is most relevant for companies at low to medium digital maturity who want to introduce data-driven decision-making without heavy investment.
Estimated Cost to Implement
Total estimated budget: €3,000–€5,000 for a basic setup
Pilot Program
What does a pilot look like for this demonstrator?
The demonstrator is installed on a selected machine using a portable sensor setup. A tap test is performed on one or more tool configurations, and the data is analyzed to generate stability diagrams. Operators are guided in adjusting cutting parameters and validating improvements during real machining operations.
Services provided during the pilot:
- On-site installation and setup of measurement kit
- Demonstration of tap test procedure
- Training session for operators (half day)
- Data analysis and stability lobe generation
- Support in selecting optimal machining parameters
- End-of-pilot evaluation report with recommendations […]
What you need to have / provide:
- A CNC milling machine
- Access to the tool and spindle area
- Basic machining program for testing
- A contact person for coordination
- Power supply and basic workspace
Contact
Partner organization: Sirris
Contact person: Samuel Milton
Role: Senior Engineer
Email: samuel.milton@sirris.be