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In actual production operations, time is money, so mechanical efficiency becomes a decisive factor for whether or not manufacturers are profitable. This has prompted manufacturers to start focusing on those leading suppliers who can provide them with methods and tools to increase productivity. Among them, the Swedish processing tool supplier System 3R International AB has developed a workpiece clamping chuck that can reduce machining vibrations. The new system can not only increase the metal cutting speed, but also improve the accuracy and reduce the wear of milling machines and other machining centers. In actual production operations, time is money, so mechanical efficiency becomes a decisive factor for whether or not manufacturers are profitable. This has prompted manufacturers to start focusing on those leading suppliers who can provide them with methods and tools to increase productivity. Among them, the Swedish processing tool supplier System 3R International AB has developed a workpiece clamping chuck that can reduce machining vibrations. The new system can not only increase the metal cutting speed, but also improve the accuracy and reduce the wear of milling machines and other machining centers.
Ordinary chucks do not fully control the vibration of the workpiece due to the dynamic forces generated by the cutting tool's impact and rotation. Therefore, in order to avoid instability in the processing flow, the operator reduces the cutting speed so that the machined workpiece meets the required accuracy. However, even at low speeds, there are still some vibrations that cannot be eliminated, which can cause gouges and creases on the ends of the workpiece. So the workpiece needs two or three steps to eliminate defects and get a smooth workpiece end. Low speeds and additional processing not only extend the time of the entire machining process, but also accelerate the wear of the cutting tool, which has to be replaced frequently.
Vibration damping advantages
The working speed and processing quality of the processing system mainly depend on the dynamic stability among the three main components in the elastic system: the machine tool, the tool and the workpiece clamping system. The machine tool industry has long studied extensively how to improve the stability of cutting tools and machining centers. However, only a few of them work to study the dynamic characteristics of the workpiece holding system. The workpiece clamping system is usually a rigid part. System 3R spent many years studying the dynamic characteristics of the clamping system. It pioneered the invention of a vibration-damping pallet chuck (VDP) and applied for a patent. The new vibration-reducing tray system incorporates a viscoelastic polymer and metal backing within the structural stiffness to improve the system's vibration damping performance. The new VDP absorbs workpiece vibrations and most of the cutting tool vibrations, thereby increasing the dynamic performance of the entire machining process. This allows operators to run the machining center at higher speeds, reducing tool wear while increasing machining accuracy. Parts processing can therefore be achieved in one step, meeting both strict dimensional tolerances and helping to reduce the end roughness to one micron. Due to the unique performance of VDP, many manufacturers favor this product, and companies that use VDP to manufacture precision parts also benefit from it. 
According to Bojan Stefanov, general manager of Swedish auto parts supplier Lidingö Produktion AB, their five-axis milling machine uses VDP damping chucks. Now it is possible to use components that previously required secondary machining in only one process to achieve the desired smooth end surface. degree. Not only that, they found that the speed of the machine tool has doubled and the service life has doubled.
Similarly, the German Ingersoll cutting tool company uses VDP to manufacture titanium alloy aircraft parts, shortening the machining time by 32% and improving the surface finish by 72%. Portuguese MGM Molds uses VDP to reduce the processing time of copper electrodes by 40%. Japan's Epic Yamada produces precision molds for semiconductors, using VDP to cut processing time by half and extend the life of tools used in machining. A Swiss company that manufactures high-speed milling machines has improved the milling process using VDP chucks. At a steering speed of 10,000 rpm, the cutting depth has been doubled, from the original 3mm to 9mm, and the metal processing speed has been greatly improved.
The future business prospects of VDP are very optimistic. According to statistics from the Gardner Institute, global investment in the machine tool industry increased by 70% since 2001, and the growth rate in 2006 was more than 10%, reaching 59.6 billion US dollars. The continuous development of the machine tool industry will increase VDP sales in this industry, and many machine tool builders are very interested in integrating VDP into their products.
The key role of vibration testing
Dr. Amir Rashid, R&D Manager of System 3R, has been leading the team in designing new products for the company and is also responsible for VDP product development. In the VDP project, engineers adjusted the VDP's pre-load by adjusting the thickness and the size of the profile to fine-tune the VDP so that it could reduce the predicted vibration load. During the entire process, these vibration loads would It changes with the cutting of the workpiece material.
"The designed structure has enough static stiffness and high dynamic stiffness to reduce machining vibrations in the desired frequency range while clamping the workpiece in the exact position," Rashid said. “The difficulty lies in precisely determining the amount of damping required within the expected frequency range while maintaining sufficient stiffness. In our development process, LMS Test.Lab software plays a key role and can be effectively completed. Extensive vibration tests and quick analysis of data."
The LMS test system used by System 3R includes two LMS SCADAS III data acquisition front-ends, each equipped with eight data acquisition channels and built-in signal conditioning. Each front end is connected to LMS Test.Lab software, enabling test control, measurement, results analysis, data management, and report generation on a unified, integrated platform. 
Rashid explained that at the beginning of the development process, vibration tests were performed on parts and machining centers that did not have VDP. Engineers install the accelerometers in different positions and use force hammers to strike structures to determine their dynamic characteristics. Tests at various speeds in working conditions measure system vibrations at different operating frequencies of the machine.
Based on the data collected from these tests, LMS Test.Lab constructs an animated mode shape and an operational deformation pattern (ODS) to show the hardware deformation. In addition, the vibration amplitude in the time domain is converted to frequency domain analysis through the Fourier transform, and the system's response at various frequencies can be further studied. In these frequency plots, LMS Test.Lab uses a “columnâ€-like colored spike to clearly identify the resonant frequency, eliminating the need to spend hours more time finding resonant frequencies from the raw FRF data. LMS Test.Lab's automation features save a lot of time for this project, and it maintains data consistency while maintaining greater accuracy.
The analysis function of the vibration data enables the engineer to calculate the energy transmitted through the component to determine the damping level required to design the contact surface of the clamping device. Based on previous practical experience, engineers understand the absorption properties of polymers, so they set the size of the contact surface to achieve the desired damping effect.
Based on these specific requirements, VDP physical prototypes were constructed and the same structural modal tests and working conditions tests were performed. Using LMS Test.Lab to test the machining process, it was shown that the measured vibration amplitude of the workpiece with the VDP system installed was reduced. Comparing the test data between the installation of VDP and that without VDP measurement, and through trial and error tests to adjust the design of the damping contact surface to minimize the vibration while maintaining the stability of the workpiece and meeting the assembly requirements of the clamping system .
The advantages of the integrated test platform
"Because of the development of new product concepts and the need for repeated vibration tests, LMS Test.Lab provides us with a unified test platform that allows us to increase the speed and accuracy of our tests," Rashid said. “Previously, we needed a separate piece of software for data acquisition of modal and operating conditions tests, one software was responsible for modal analysis, and then a third software was used to generate a frequency chart of processing tests.†He explained that because of the Being independent of each other, different people use these software, often causing delays in the conventional development process. In addition, the exchange of data between different systems is also very time-consuming and prone to errors, because in many cases the data cannot be completely converted and therefore has to be manually operated.
"We need a separate, integrated platform to help us achieve vibration testing more quickly and accurately. We need to quickly test and get results at the same time, rather than switching between different systems. Using LMS Test.Lab, we can complete the test and analysis results in a few hours.The improvement of work efficiency is very important to us because we design various models to meet various processing applications and different workpiece sizes, including Special VDP for some customers."
Rashid believes that LMS Test.Lab's worksheets and templates are particularly useful for shortening setup time for vibration tests. "LMS Test.Lab has many worksheets for feature functions such as modal testing, time domain data processing and signal testing," he said. In addition, the template also has instrument sensitivity settings and other automated functions that are no longer needed by the engineer. The System 3R report indicates that the set-up time for the test has been reduced by at least 30%.
"LMS Test.Lab allows us to perform various vibration tests faster and more accurately, avoiding time delays and reducing the probability of errors. From a business perspective, with the rapid development of global manufacturing, we only have Innovation can stabilize the company's leading position in the global market, and the LMS system is the best partner for our technological innovation."
LMS Test.Lab Improves Metal Cutting Production Efficiency
System 3R develops a new workpiece clamping chuck based on the LMS test and test system to reduce vibration during machining