The effects of dynamic interaction between machine tool subsystems on cutting process stability

The dynamic interaction between different machine tool subsystems can be exploited to increase the machine cutting performance. Simplified models are proposed to define useful guidelines that maximize the material removal rate in milling processes in different industrial situations. Two different cases are presented: in the first one, the machine influence on spindle dynamics is considered and optimized. In the second case, the interaction between the control system and the machine tool mechanical structure is analyzed, suggesting control tuning criteria that maximize cutting process stability. The procedure is applied to a real industrial case: a five-axis machine tool with a bi-rotative head. Moreover, requirements for the applicability of the proposed approach are investigated and described by analytical formulas.