Case Study 1.3: Auto-adaptive Vibrations and Instabilities Suppression in General Milling Operations

In general rough-milling operations, unstable tool vibrations due to the interaction between process forces and tool flexibility could arise. The onset of these unstable vibrations, usually referred to as chatter, poses limitations in terms of the achievable material removal rates, hence directly impacting on the productivity. Moreover, chatter vibrations generally lead to an increase in tool wear, imposing premature tool changes and careful monitoring of the process, potentially impeding unmanned operations. Within the INTEFIX project, an active fixture prototype was developed to detect and mitigate the level of chatter vibrations in general rough-milling operations with the purpose of improving the achievable material removal rates. This contribution covers the main aspects of the global development of this prototype, from the mechanical design to the adaptive control logic used in order to drastically reduce the inputs and expertise required for its operability.