Control systems and methods for machining operations

A method for controlling a machining operation wherein a tool performs a machining operation on a work piece, comprising

• (a) providing a tool holder for holding the tool, a work piece holder for holding the work piece, a linear slide for linearly moving a linearly moving part comprising at least one of the tool and work piece, a rotator for rotating a rotating part comprising at least one of the tool and work piece, a modulator for modulating the movement of a modulated part comprising at least one of the tool and work piece, and a digital controller for controlling the machining of the work piece by the tool, wherein the digital controller is capable of sending a control signal for controlling the operation of at least one of the linear slide, rotator and modulator,
• (b) selecting a set of appropriate machining parameters to employ for enabling the tool to perform a desired machining operation on the work piece, the step of selecting a set of appropriate machining parameters including the steps of:
• (1) selecting an appropriate feed rate for the linear slide to move the linear moving part;
• (2) selecting an appropriate rotational speed for the rotation to rotate the rotating part;
• (3) selecting an appropriate modulation amplitude for the modulator to employ to move the modulated part an appropriate distance in a cycle;
• (4) selecting an appropriate modulation frequency for the modulator to employ to move the modulated part an appropriate number of cycles in a given time interval;
• (c) incorporating the set of appropriate machining parameters into the digital controller;
• (d) inputting machining parameters into an algorithm for adjusting the control signal sent by the digital controller to at least one of the linear slide, rotator and modulator for controlling the operation of at least one of the linear slide, rotator and modulator, and
• (e) using the digital controller to control the operation of the linear slide, rotator and modulator to execute the machining of the workpiece by the tool in accordance with the appropriate set of parameters,
• wherein the machining parameters are selected from the group consisting of the feedrate a (mm/rev), workpiece or tool rotational speed fw (RPM), of cutting edges n, and the diameter of the drill or workpiece D (mm).