Methods for measuring a resonance frequency of a tool set in ultrasonic vibration during the machining of a workpiece, involving radiating a working signal with a working frequency into a tool holder comprising a tool by a generator to produce the ultrasonic vibration of the tool; after the start of the machining of the workpiece, radiating a test signal with a test frequency varying by the working frequency and a lower power than the working signal power into the tool holder by the generator; generating a sensor signal from the ultrasonic vibration of the tool by a sensor apparatus arranged in the tool holder; reading out the sensor signal by a read-out apparatus; splitting the sensor signal into a frequency spectrum involving a main frequency and an auxiliary frequency by an analytical apparatus; determining the main frequency from the working frequency and the auxiliary frequency from the resonance frequency.

Methods for measuring a resonance frequency of a tool set in ultrasonic vibration during the machining of a workpiece, involving radiating a working signal with a working frequency into a tool holder comprising a tool by a generator to produce the ultrasonic vibration of the tool; after the start of the machining of the workpiece, radiating a test signal with a test frequency varying by the working frequency and a lower power than the working signal power into the tool holder by the generator; generating a sensor signal from the ultrasonic vibration of the tool by a sensor apparatus arranged in the tool holder; reading out the sensor signal by a read-out apparatus; splitting the sensor signal into a frequency spectrum involving a main frequency and an auxiliary frequency by an analytical apparatus; determining the main frequency from the working frequency and the auxiliary frequency from the resonance frequency.

A system, method and computer-readable medium for fine-tuning speed selection for reducing machine chatter. The system includes circuitry configured to determine a predetermined speed of the machine. The circuitry identifies a stability lobe based on the predetermined speed of the machine and selects a first set of fine-tuning speeds from a range of machine speeds corresponding to the determined stability lobe. Further, the circuitry causes the machine to operate at one or more of the first set of fine-tuning speeds.

A system, method and computer-readable medium for fine-tuning speed selection for reducing machine chatter. The system includes circuitry configured to determine a predetermined speed of the machine. The circuitry identifies a stability lobe based on the predetermined speed of the machine and selects a first set of fine-tuning speeds from a range of machine speeds corresponding to the determined stability lobe. Further, the circuitry causes the machine to operate at one or more of the first set of fine-tuning speeds.

A controller for controlling a synchronized operation of spindle and feed axes. A spindle-axis control section includes an initial-motion control section for making a spindle axis perform an accelerated rotation at maximum capacity from a process start position; a maximum-acceleration detecting section for detecting a maximum acceleration of the spindle axis; a residual rotation-amount detecting section for detecting a residual rotation amount of the spindle axis; a current-speed detecting section for detecting a current speed of the spindle axis; a decelerating-motion control section for making the spindle axis perform a decelerated rotation at a gradually increasing deceleration so as to reach an intermediate rotation speed after the accelerated rotation; and a positioning-motion control section for making the spindle axis perform a decelerated rotation at maximum capacity so as to reach the target thread depth after reaching the intermediate rotation speed.

A controller for controlling a synchronized operation of spindle and feed axes. A spindle-axis control section includes an initial-motion control section for making a spindle axis perform an accelerated rotation at maximum capacity from a process start position; a maximum-acceleration detecting section for detecting a maximum acceleration of the spindle axis; a residual rotation-amount detecting section for detecting a residual rotation amount of the spindle axis; a current-speed detecting section for detecting a current speed of the spindle axis; a decelerating-motion control section for making the spindle axis perform a decelerated rotation at a gradually increasing deceleration so as to reach an intermediate rotation speed after the accelerated rotation; and a positioning-motion control section for making the spindle axis perform a decelerated rotation at maximum capacity so as to reach the target thread depth after reaching the intermediate rotation speed.

A controller for controlling a machine tool calculates a variation of a cutting load based on a changed rotational speed or feed rate of a tool in a machining program for machining a workpiece when the rotational speed or the feed rate is changed, and executes the machining program if the changed rotational speed and/or feed rate of the tool and/or the cutting load are within the ranges of predetermined upper and lower limit values.

A controller for controlling a machine tool calculates a variation of a cutting load based on a changed rotational speed or feed rate of a tool in a machining program for machining a workpiece when the rotational speed or the feed rate is changed, and executes the machining program if the changed rotational speed and/or feed rate of the tool and/or the cutting load are within the ranges of predetermined upper and lower limit values.

A smart tool system may include at least one assembly of a tool holder and a tool, and a tooling machine configured to rotate the at least one assembly to cut a workpiece. The tooling machine may have a spindle to which the tool holder may be selectively attachable, and a controller configured to rotate the spindle at a spindle speed. The smart tool system may also include at least one database configured to store vibrational data relating to at least one of the at least one assembly and the tooling machine. The smart tool system may further be configured to determine an optimum operating value and/or range of optimum operating values of at least one parameter for the tooling machine based on the vibrational data. The optimum operating value(s) provide for minimized or no chatter when cutting the workpiece.

A smart tool system may include at least one assembly of a tool holder and a tool, and a tooling machine configured to rotate the at least one assembly to cut a workpiece. The tooling machine may have a spindle to which the tool holder may be selectively attachable, and a controller configured to rotate the spindle at a spindle speed. The smart tool system may also include at least one database configured to store vibrational data relating to at least one of the at least one assembly and the tooling machine. The smart tool system may further be configured to determine an optimum operating value and/or range of optimum operating values of at least one parameter for the tooling machine based on the vibrational data. The optimum operating value(s) provide for minimized or no chatter when cutting the workpiece.