Abstract: A composite material includes a plurality of metallic particles formed through modulation-assisted machining. The composite includes a thermoplastic polymer matrix which binds the plurality of metallic particles.

Abstract: A tool holder is provided for holding one of a tool and workpiece. The tool holder is configured for mounting to a driving member of a machining device. The tool holder includes a tool holder first end including a coupler for coupling the tool holder to the driving member of the machining device. A tool holder second end includes a clamp for releasably holding one of the tool and workpiece. A force sensor is disposed between the clamp and the coupler for sensing force exerted on the one of the tool and workpiece held by the clamp. A linear actuator is disposed between the clamp and the force sensor for linearly moving the one of the tool and workpiece.

Abstract: A modulating tool holder includes a tool holder first end and a tool holder second end, and a central axis extending between the tool holder first end and the tool holder second end. The tool holder first end has a coupler for coupling the tool holder to a drive member of a machining device and the second end includes a clamp for releasably holding either a tool or a workpiece. A rotatable spindle member extends axially in the tool holder and imparts a rotational movement to the clamp. A central fluid passageway extends between first and second ends of the rotatable spindle member for conveying a fluid. A linear actuator is configured to impart an oscillating movement to the clamp. The linear actuator is functionally decoupled from the torsional load of the rotatable spindle member.

Abstract: Assemblies, apparatus, and methods are described for designing modulation tool holder assemblies and installations for modulation-assisted machining, and, in particular, for rotating machining applications that benefit from the sinusoidal modulation motion while cutting fluids are simultaneously applied through the tool. In addition, the design of rotating modulation tool holder assemblies and systems is described. In a tool holder assembly for modulation in a rotating spindle, the electric power and/or control signals are transferred from an external source to the modulation tool holder assembly installed in the rotating machine spindle. Similarly, the high-pressure cutting fluid is transferred from a stationary source to the rotating tool holder assembly for modulation.

Abstract: Assemblies, apparatus, and methods are described for designing modulation tool holder assemblies and installations for modulation-assisted machining, and, in particular, for rotating machining applications that benefit from the sinusoidal modulation motion while cutting fluids are simultaneously applied through the tool. In addition, the design of rotating modulation tool holder assemblies and systems is described. In a tool holder assembly for modulation in a rotating spindle, the electric power and/or control signals are transferred from an external source to the modulation tool holder assembly installed in the rotating machine spindle. Similarly, the high-pressure cutting fluid is transferred from a stationary source to the rotating tool holder assembly for modulation.

Abstract: A method is provided for controlling a machining operation wherein a tool performs a machining operation on a workpiece. The method includes providing a tool holder for holding a tool, a workpiece holder for holding a work piece, and a linear slide for linearly moving a linearly moving part that is either the tool or the workpiece. The step of selecting appropriate machining parameters includes the step of selecting an appropriate feed rate for the linear slide move the linear moving part and appropriate rotational speed is selected for the rotator to rotate the rotating part. The set of appropriate machining parameters are incorporated into the digital controller. The digital controller is then used to control the operation of a linear slide, rotator and modulator to execute the machining of the workpiece by the tool in accordance with a selected appropriate set of parameters.