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The MAKING CHIPS Podcast for Manufacturing Leaders with Jason Zenger & Jim Carr

Welcome to MakingChips - We believe that manufacturing is challenging, but if you are connected to a community of leaders, you can elevate your skills, solve your problems and grow your business. Making Chips is a weekly podcast that will EQUIP and INSPIRE MANUFACTURING LEADERS to succeed in the challenging world of manufacturing. Our mission is for the METALWORKING NATION to Think Differently About Manufacturing In Order to Elevate their Game. Your hosts, Jason Zenger & Jim Carr, own manufacturing businesses and interview other leaders in the metalworking, machining, fabrication, tooling and machine tool industries. We have interviewed successful manufacturing CEOs you may have not heard of and also the biggest names in manufacturing like Titan Gilroy from Titans of CNC, John Saunders from NYC CNC, Mark Terryberry from Haas Automation and others from MakerCast, Sandvik Coromant, Autocrib and more. Think of us as your virtual community of manufacturing peers to help solve your toughest problems and grow your business. "Making Chips has provided a transparent approach to sharing within the manufacturing community and a modern platform to do so. Thank you both for taking the lead on moving our industry segment forward!" Patricia Miller - CEO & Visionary (Matrix IV) I really think what you guys are doing is a great, great thing for manufacturing. I have learned so much already from many of your episodes, and am so thrilled to have met people that get as revved up about manufacturing as I do! Cassandra Haupers – Vice President of Operations (Swiss Precision Machining) I love being able to experience what manufacturers are doing to promote culture and engage their team members and community. All of us are smarter than one of us. That is why I am part of the Making Chips tribe. Barry E. Walter, Jr. – Chief Operating Officer (Barry E. Walter, Sr. Co.) Finally, relevant manufacturing media that is actually entertaining! Dietmar Goellner – Chief Executive Officer (Advanced Machine & Engineering / Hennig) The more manufacturing companies we can get to think this way, the stronger our industry will be. Thank you for sharing! Jess Giudici – Manager, Talent and Culture I’m thankful to you for creating MakingChips for the Metalworking Nation so that Owners / Employees can strengthen their companies. Phil Sponsler – President (ORBITFORM) I love the podcast! It really serves to fill a void in the manufacturing world. I will admit I always feel a little more inspired. Jason Falk – Senior Application Engineer, CMTSE (HURCO) Thanks to all the great info on your podcasts and the website. Dave Lechleitner – Director of Solutions and Product Marketing (KEYEDIN) I really love what you guys are doing to advance the mfg industry in a way that really reaches the right audiences. Jeff Rizzie – Senior Manager-Business Development (Sandvik Coromant)
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Dec 28, 2018

The MakingChips podcast welcomes guest Tony Schmitz, professor at UNC Charlotte and assistant director, energy production and infrastructure center to talk about machining vibration. Tony teaches mechanical design, helping students design and build useful technology like robots. He also teaches mechanical vibrations, structural dynamics, and advanced manufacturing. He says, “At the end of the day, when you’ve made something, you never feel like you didn’t accomplish something that day.” During this episode, Tony gives helpful information about how to measure and mitigate machining vibration in manufacturing.

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The 3 pieces of the machining dynamics puzzle

Why are machining dynamics important for manufacturing leaders? Knowing the variables within a tooling machine and being able to adjust them appropriately can increase the longevity of the tool and increase productivity. Tony Schmitz explains that there are three pieces of the machining dynamics puzzle. Listen as he explains why considering these three factors are essential for manufacturers.

Feel the machining vibration

Whenever a force is being applied to a nonrigid structure, there will be vibration. The problem, according to Tony, is that CAD/CAM software encourages you to ignore vibration and the variables within the machining tool. CAD/CAM always drafts the cutting process perfectly. However, it doesn’t take into account the reality of a machining tool that vibrates. Vibration means displacement of your cutter that changes over time. However, Tony says that the math equations you learned in school can actually be applied to the shop floor. Hear how differential equations can actually be used in CAD/CAM software to help get higher axial depths of cut without chatter.

Good vibrations v. bad vibrations

“Just like we all have fingerprints, every cut has a fingerprint as well and it’s the frequency content of that sound signal,” says Tony Schmitz. Bad vibration, also called chatter, are unmistakable when you hear it in a shop. Tony talks about how he can analyze frequencies that a machine puts out and identify bad vibrations and problems in the chip making process. He also explains how viewing wave patterns produced by a machine can tell you how to adjust your spindle speed. Tony says, “The most powerful knob on your controller is not the feed override, it is the spindle speed override.”

How to increase productivity in your shop

In order to mitigate bad vibration and increase your productivity, Tony encourages collecting a minimum set of data. He describes how to select the 8-10 standard tools that you use the most and collect data on those tools, using an impact, or tap test. Results from a tap test can help you bid jobs more accurately. They can also help you make adjustments to your machines so that you can avoid chatter and be more efficient. Learn about that and much more on this episode of MakingChips.

Here’s The Good Stuff!

  • Manufacturing News: A Detroit entrepreneur applies lean auto manufacturing principles to build a beauty salon
  • Introduction of guest Dr. Tony Schmitz, professor of at UNC Charlotte and Assistant Director, Energy production and infrastructure center
  • Tony explains the three pieces of the machining dynamic puzzle
  • How math and physics can be applied to the shop floor
  • Analyzing frequency data to identify bad vibrations within a machining tool
  • The correlation of feedback in a PA system and chatter in a milling tool
  • How a tap test can help you measure your tools data, make adjustments, and increase productivity
  • The pigskin professor and how Dr. Tony Schmitz put together videos for University of Florida football games

This Week’s Superstar Guest

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