This paper presents a novel approach for active chatter reduction using a motor spindle with integrated magnet actuators. Based on the results of previous studies the design of an active damped prototype is described. The system performance as well as the benefits and drawbacks of this solution are discussed. In order to eliminate the known drawbacks a novel actuator design is introduced. The novel approach integrates the actuator windings into the stator core. Next, strategies for electric and magnetic decoupling of the actuator and motor windings are presented. Subsequently the actuator design is discussed. The force generation and distribution of the damping actuator are calculated via analytical and finite elements analysis (FEA). With the novel approach the mechanical integration of the active damping actuators is simplified significantly. Additionally, the maximal attainable spindle power is increased up to 150% in relation to the previous solution.

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