The material removal rates of machine tools are often limited by chatter, which is caused by the machine’s most flexible structural modes. Active vibration control systems mitigate chatter vibrations and increase the chatter-free depth of cut. The systems can be used for already-in-use machine tools in particular as a retrofit solution. Unfortunately, no dimensioning techniques exist to help in finding the right actuator size required for a specific machine tool. This publication presents a simulation-based dimensioning methodology that determines, based on a stability analysis, the required actuator force and bandwidth. First, the critical machining processes, based on machine tool specific parameters, are identified. Then, the required actuator force and bandwidth are determined with the help of a coupled simulation model that consists of a cutting force model, the machine’s structural dynamics, and a model of the active vibration control system.

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