Dynamic analysis of a motor-integrated method for a higher milling stability

The productivity in High Speed Cutting is often limited by undesirable vibration effects in the main spindle (chatter). In many cases these limits are far below the technically possible cutting parameters provided by the machine technology. This paper presents a new approach to a motor-integrated milling spindle with an embedded electromagnetic actuator to actively reduce chatter vibrations and increase productivity. It is based on the non-contact application of highly-dynamic damping forces on the spindle shaft. That way the process stability can be increased significantly. By measurement and simulation-based analysis of spindle dynamics and transient and analytical approaches to process stability, the efficiency of the damping method is demonstrated in theory. Finally, a new, soft magnetic composite based motor-integrated electromagnetic actuator is introduced in this article.