SIREN · Stability Islands: Performance Revolution in Machining

Cutting went through a revolution in the 1990s when high-speed milling (HSM) was introduced: the sculpture-like workpieces produced with high precision and efficiency resulted in one order of magnitude less parts in cars/aircrafts, which kept this traditional technology competitive at the turn of the century. This has been followed by an incremental development when not just the cutting speeds, but depths of cut and feed rates are pushed to limits, too.The limits are where harmful vibrations occur. Cutting is subject to a special one called chatter, which is originated in a time delay: the cutting edge interferes with its own past oscillation recorded on the wavy surface cut of the workpiece. In 1907, the 3rd president of ASME, Taylor wrote: “Chatter is the most obscure and delicate of all problems facing the machinist”.In spite of the development of the theory of delay-differential equations and nonlinear dynamics, Taylor’s statement remained valid 100 years later when HSM appeared together with a new kind of chatter. The applicant has been among those leading researchers who predicted these phenomena