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Our digital twin is used to simulate millions of combinations of machine settings to arrive at the optimum feed rates and spindle speeds setting for a given process prior to manufacturing.
Every machine tool generates unique resonant frequencies that can be diagnosed via a simple tap test using equipment supplied by our partner, Kistler. This resonant frequency diagnosis is an essential input to our digital twin for the analysis across the toolpath using specific cutting tools.
We combine tap test data with our optimization to produce a stability map, identifying chatter-free spindle speeds.
A human operator with years of experience cannot be certain that the best settings have been achieved; the optimum combination is not necessarily intuitive but thanks to our unique stability map, we eliminate harmful chatter vibrations across the toolpath providing increased productivity and superior part quality.
Increase productivity, reduce cycle times and save money with easy to use subscription app
Avoid wasted time, energy & material. First-time manufacture with fewer iterations
Eliminate errors and produce parts with optimal surface finish and dimensional accuracy
Monitor spindle health and prevent unplanned downtime
Bring expert machining strategies to the shop floor
Carry out shop floor machine tool acceptance tests
Chatter elimination optimizes the cutting, reducing material waste and supporting sustainable manufacturing practices.
The longer cutting-tool life achieved through chatter reduction means less need for frequent replacements.
Reduced vibrations lead to lower electricity consumption during machining.
Chatter elimination results in improved product precision, reducing defective parts.
Smoother machining operations reduce machine wear, prolonging the life of CNC equipment.
Reduced cutting noise improves workplace safety and contributes to a healthier workplace.
This web app offers instant optimized feed rates applied to straight milling operations with a flat end cutter. It can be used for process planning of untested milling operations to diagnose production issues by prediction of cutting forces the cutting tool experiences in the process. Its output can also be used while designing fixtures for the milling process.
Axial and radial depth of cut
Spindle speed / Cutting speed
Workpiece material (Steel, Aluminium, Titanium, Inconel)
Operation type (down milling, up milling, slotting)
Tool geometry (diameter, number of flutes, helix angle, pitch angle, rake angles)
Cutting Forces in Feed, Cross Feed and Axial directions
Side Load (Resultant of Feed and Cross Feed forces)
Maximum chip thickness
Material Removal Rate (MRR)
Feed-rate optimization for a user defined process characteristics constraint
The Spindle Speed Calculator app helps
engineers to select the right set of
parameters for profiling providing spindle
speed and depth of cut combinations to
achieve stable milling processes.
Tool geometrical features
To predict and identify the stability of machining operations against chatter vibration before cutting any metal
To assess the process transferability between the machine tools in the shop floor
To support the machine tool acceptance tests
Identify safe spindle speeds for machining by combining an
understanding of the behaviour of the installed cutting tool and
Try our Optimization to reach the best part, faster, right first
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Get one year free Essential Optimization and tap test training
you buy DigiTap standalone software and our tap test hardware kit.
Inspect the health of your spindle to
extend tool life and prevent downtime
(requires FRF data).
Apply optimal feed rates to optimize the cutting forces of your machining process to increase speed.
(when billed annually)
Apply optimal Feed Rates and Spindle Speeds to achieve the fastest chatter-free results (requires FRF data).
(when billed annually)
Gain insights into your machine's dynamics by collecting and analysing FRF data with our tap test hardware kit and DigiTap standalone software application.