A system for damping machine-induced vibration in a workpiece includes a plurality of workpiece holders to hold the workpiece in a work cell. The system also includes a machine tool located in the work cell. The machine tool performs a machining operation on the workpiece while the workpiece is held by the plurality of workpiece holders. The system further includes a damping apparatus coupled to the workpiece. The damping apparatus controls machine-induced vibrations in the workpiece during the machining operation.

A system for damping machine-induced vibration in a workpiece includes a plurality of workpiece holders to hold the workpiece in a work cell. The system also includes a machine tool located in the work cell. The machine tool performs a machining operation on the workpiece while the workpiece is held by the plurality of workpiece holders. The system further includes a damping apparatus coupled to the workpiece. The damping apparatus controls machine-induced vibrations in the workpiece during the machining operation.

A method for manufacturing a part to compensate for residual stress distortion is disclosed. The method can include obtaining a first part based on a nominal part. The first part can be distorted from the nominal part by residual stress. The method can also include determining a variation of the first part from the nominal part. The method can further include determining an offset of the variation relative to the nominal part to compensate for the variation. Additionally, the method can include making a second part using the offset of the variation, wherein residual stress distorts the second part within tolerance of the nominal part.

A sensorless method for machine tool chatter detection. A motor torque signal is analyzed in the time domain to determine whether a bit is currently cutting workpiece material. When not cutting material, an air-cut reference signal is stored for later use. When cutting material, the motor torque signal is converted to the frequency domain and filtered in a two-step process. The first filtering step includes removal of the air-cut reference signal via spectral subtraction, which removes noise and harmonics not directly related to chatter. The second filtering step includes further removal of spindle harmonic components at frequencies known from the spindle speed provided by the machine controller, where this step removes harmonic contents without distorting nearby contents. After filtering, two indicator criteria are evaluated to detect chatter, including a magnitude of the filtered torque signal and a magnitude ratio of the filtered torque signal to the air-cut reference signal.

A computer-implemented system, method, and medium of automated milling machine calibration includes receiving a 3D virtual calibration design comprising one or more designed indented regions and a designed curved region; milling the 3D virtual calibration design into a physical block to provide a 3D physical milled calibration block; receiving a 3D virtual calibration scan block of the 3D physical milled calibration block; and determining one or more calibration parameters from the 3D virtual calibration scan block.