Machining problems? Try universities

Got a machining problem? Who doesn’t? But who do you call? Certainly your machinery or tool supplier, but you might also consider contacting a university-based manufacturing research center. Not all universities, however, have machine tool and manufacturing research centers. Actually, a limited number exist.

“It depends primarily on the expertise and interests of the existing faculty,” said Tony L. Schmitz, associate professor in the Department of Mechanical and Aerospatial Engineering and Director of the Machine Tool Research Center, University of Florida at Gainesville.

Each such research center focuses on different areas of manufacturing and machine tool technologies. At the University of Florida, for example, there are three primary research issues.

First, Schmitz and his colleagues concentrate on predicting the dynamic response of the machining system. “Through our research, we’ve developed a method called ‘receptance coupling substructure analysis’ that couples models of the tool and toolholder to a measurement of the spindle and machine,” he said.

Second, they use this information to make predictions of the process behavior in terms of stable vs. unstable cutting and part accuracy due to forced vibrations.

Finally, they organize this prediction data into a user-friendly stability lobe diagram. The goal is to identify stable zones that also meet accuracy requirements.

“I see our research efforts as decreasing the time from drawing to part by improving the manufacturer’s ability to select optimal machining parameters at the process planning stage,” Schmitz said. “A preferred implementation approach for the future is to make predictive technology available via the Internet so it can be easily accessed.”

The overall thrust of the department’s research efforts is aimed at “an improved understanding of the machining process to enable machinists to select operating parameters for decreased machining cost,” he said. “For example, by selecting an axial DOC and spindle speed combination that avoids chatter without the need for test cuts, production time can be reduced.”