Frequently Asked Questions

Installation & Licensing

I am getting an Error when trying to install your software
I can't launch your software after installing it
CutPRO/ShopPRO cannot find the licensing key after undocking the laptop.
Error Hl202: An Error occurred while verifying your ShopPro/CutPro License.
My trial key AB99 stopped working before the end of my trial

Stability Lobes

Sometimes, the stability lobes do not match with cutting tests. The stability pocket with the high depth of cut chatters, while the speed at the lowest depth of cut does not. Why?
How can we obtain an ASCII text file for the stability lobes?
What are the steps in predicting the stability lobes?
What is the use of time domain simulation of stability lobes.
Multiple analytical stability lobes.
In the construction domains of stability, frequency starting at 800 rev / min. How to be the processing of Titanium, if we work at the speed of 800 rev / min.
The stability lobes don't match at high speeds.

Frequency Response (FRF)

Measurement of Flexible End Mills.
Database design to avoid repetative tap testing.
At what point can you decide whether the coherence of your tap test is insufficient in order to create good stability lobes. Does it depend from which frequency the signal starts to drop or drops completely? And what to do when there's no way to get a better coherence?
Measurement of Slender End Mills with small diameters.

Troubleshooting the source of vibrations during machining

The machining process excites one of the flexibilities that exist on the tool/machine tool or workpiece/fixture side. Each flexibility has a natural frequency and associated mode shape (i.e. how the structure behaves during vibrations).

The following procedure can be used to identify the source of the flexibility and weak joint on the machine/tool – fixture/workpiece set up:

1) Conduct a chatter test and measure the vibration using microphone or accelerometer. Use a new CutPro Data Acquisition Cutting Test workspace and enable the continuous data logging mode.
2) Apply FFT (Fast Fourier Transform) using Data Acquisition’s FFT button (located on the plot toolbar) where the chatter is evident with large amplitudes. Identify the chatter frequency and record it.
3) Conduct impact hammer tests on the cutting tool mounted on the spindle using CutPro Tap Testing. Check the natural frequencies from the Magnitude of the measurement. If the natural frequency of the tool measurement is very close to chatter frequency, the chatter is caused by the machine tool or cutting tool assembly.
4) Conduct hammer tests on the workpiece mounted on the fixture using CutPro Tap Testing. Check the natural frequencies from the Magnitude of the measurement. If the natural frequency of the workpiece measurement is very close to chatter frequency, the chatter is caused by the workpiece, fixture or clamping.

Identification of flexible joint that causes chatter

To determine the source of vibrations, please see the previous FAQ “Troubleshooting the source of vibrations during machining”.

If the tool side is causing chatter:
(You can use 1D modal analysis and look at Lathe example in CUTPRO’s Example folder: C:\Program Files (x86)\CutPro\Examples\Modal Analysis\1D Modal Analysis)

1) Mark points along the tool – fixture – spindle (i.e. tool tip-1, middle of the stick out-2, close to the tool holder-3, tool holder but close to the tool clamping-4, tool holder close to the spindle flange–5, spindle nose-6). Stick the accelerometer at the tooltip (Point 1) and keep it at point 1, and apply impact at point 1 (FRF Measurement H11), point 2, …, point 6.
2) Load the measurements into CutPro Modal Analysis Module; select the high peaks (natural frequencies), especially the one which is close to the chatter frequency.
3) Display the mode shape which corresponds to the chatter frequency. Mode shape will show you how the tool-holder-assembly is behaving during chatter.

• If the mode shape shows that the deflection is a continuous from the spindle nose-holder-tool, the whole spindle is vibrating.
• If the tool holder is sharply deflecting away from the spindle nose, the holder-spindle interface is either worn or connection is weak due to dust or chip stuck in the spindle taper. If not, the holder is weak.
• If the tool is deflecting away from the holder-joint sharply, the tool-holder joint is not stiff enough. Tighten the holder or use shrink fit. If the tool is deflecting with the curved shape, the tool is too long and flexible.

If the workpiece side is chattering
(You can use 2D modal analysis example in the CUTPRO Example folder C:\Program Files (x86)\CutPro\Examples\Modal Analysis\2D Modal Analysis)

1) Mark points on the XY plane of the workpiece – fixture set up. Stick the accelerometer at one point (1) which seems to be most flexible.
2) Apply impact at each point while keeping the accelerometer at the same point (Point 1), and save the measurements.
3) Load the measurements in Modal Analysis (2D analysis). Check the mode shape which has the closest natural frequency with the chatter frequency. Mode shape will show you the clamping or workpiece locations which deflect most. If the deflections occur at the workpiece – fixture contact points, place the clamps at the points where you see the largest mode shape deflections.

Difficult to Cut Materials

Problems in low speed milling of steel, Titanium and hard materials.
How can we increase the productivity in low speed milling of Titanium, Inconel, and Stainless Steel alloys?
High speed milling of Titanium alloys.

Soft Materials

High Speed milling of Aluminium

Other

Dimensional and Surface Location Errors in CUTPRO.
What is the influence of work material on the chatter?
With regard to tool geometry in some cases we have tools with different helix angle or serrated and continuous flutes and other variations which are not given has input to the software. So whether these parameters have any effect and if they have any effect on machine stability how are they incorporated into the software?
Since the measurements with an accelerometer and hammer are obtained without any machining process (without tool touching the workpiece), the effects of the workpiece setup and workpiece holder on machine dynamics are not measured. If they have any effect, then how it can be incorporated into the stability lobe calculation?
The use of small diameter end mills in CutPRO and ShopPRO
Milling thin walls and webs.
How do you select impact hammers and accelerometers?
Can someone give me the procedure on how to check if your spindle is worn or not.

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