Manufacturing Laboratories' Dr. Tom Delio was one of the original partners of the Boeing Advanced Manufacturing Research Center (AMRC) at the University of Sheffield. Today, Machining Dynamics (tap-testing) is a fundamental technology expertise of the AMRC as described by this video:
Here is the AMRC's Machining Capability Guide (see page 7)
The AMRC has spun-off numerous new centers, including the Nuclear AMRC. Tap-testing is a core competency of the NAMRC.
Tap-testing is a powerful technique that could provide significant cost savings compared with using conservative cutting parameters or trial-and-error tuning of cutting parameters...”
Optimizing machining performance has helped innovative high precision engineering company Produmax double its turnover and the number of people it employs and laid the foundations for similar growth in the future. A combination of Ballbar and Tap testing enabled the company to optimize the physical performance of its machine tools..."
The advanced machining methods used by this shop deliver machining times that are two-three times quicker than previously possible for tough, complex aerospace components. With resonance measurement (tap-tests), accelerometers are fitted to the cutter. Readings are taken to establish the best cutting conditions and methods to maximize metal removal rates by taking much deeper cuts than would normally be possible, avoiding problems commonly found when cutting titanium, such as burning the tool and chatter that can damage the material and lead to high scrap rates..."
AML’s raison d’etre is to take a part, however complex and establish the most productive and economical way of manufacturing it – from prototype through to full batch production. It achieves this via a number of scientific methods centered around machine dynamics optimization such as Tap Test Analysis..."
With resonance measurement, accelerometers are fitted to the cutter and, in some cases, the billet. Readings are then taken to establish the best cutting conditions and methods. Using this technology enables the company to maximise metal removal rates by taking much deeper cuts than would normally be possible, avoiding problems commonly found when cutting titanium such as burning the tool and chatter which can damage the material and lead to high scrap rates. Dr Gareth Morgan says, “Resonance technology was my field of study for my PhD, so we are well advanced in its use. For aerospace parts we are working with aggressive materials and we are frequently removing over 80% of them, so this is a very important technique for us..."