Machined Workpiece Research Articles

Development of an Automatic Robotic Procedure for Machining of Skull Prosthesis

The project presented in this paper develops within the field of automation in the medical-surgical sector. It aims at automating the process for the realization of prosthetic devices for the skull in cranioplasty, following a craniotomy intervention for brain tumor removal. The paper puts emphasis on the possibility to create the prosthetic device in run-time during the surgery, in order to ease the work that surgeons have to do during the operation. Generally, a skull prosthesis is realized before the day of the intervention, based on the plan of the medical operation, on the results of computed tomography, and through image processing software. However, after the surgery is performed, a non-negligible geometrical uncertainty can be found between the part of the skull actually removed and the cut planned during the preliminary analysis, so that the realized prosthesis (or even the skull, at worse) may need to be retouched. This paper demonstrates the possibility to introduce a fully automated process in a hospital environment, to manufacture in runtime the prosthetic operculum, relying on the actual geometry of the incision of the skull detected during the intervention. By processing a 3D scan of the skull after the craniectomy, a digital model of the prosthesis can be created and then used as an input to generate the code to be run by a robotic system in charge of the workpiece machining. Focusing on this second step, i.e., the manufacturing process, the work describes the way the dimensions of the raw material block are automatically selected, and the way robot trajectories for milling operation are automatically generated. Experimental validation demonstrates the possibility to complete the prosthesis within the surgery time, thus increasing the accuracy of the produced prosthesis and consequently reducing the time needed to complete the operation.

Key manufacturing technologies of the CFETR 1/8 vacuum vessel sector mockup

• Key technology types involved in CFETR 1/8 V V sector model. • Methods and routes of key technologies of CFETR 1/8 V V sector model. • Current manufacturing progress of CFETR 1/8 V V sector model. This paper introduces key technologies and main advances in the development of the 1/8 vacuum vessel (VV) sector mockup of China fusion engineering test reactor (CFETR). The contour accuracy of each VV shell is controlled within ±2 mm through hot forming, solution treatment, and correction of each hyperboloid shell, and cold forming of the single-curved shell. The welding structure between the 1/8 sectors of CFETR VV on site is simulated by using the welding structure between two 1/16 VV sectors as a model. The narrow-gap TIG (NG-TIG) welding process is designed and explored in the sector welding of the 1/32 VV sector. Electron beam (EB) welding of the port stub is completed, and the weld quality meets the design requirement. The results of phased array ultrasonic testing (PAUT) technology reveal that the testing process meets RCC-MR technical requirements and solves the problems of full volume coverage (i.e., missed detection) and signal-to-noise ratio (i.e., misjudgment) of austenitic stainless steel welds. The automatic ray film arrangement trolley can achieve the automatic arrangement of the X-ray film between double shells when the VV is welded on-site. The measurement solution of three-dimensional complex space solves the problem of collimation positioning measurement during the welding, machining, and assembly of the 1/8 VV sector. The results of the study on the virtual assembly and reverse machining technology provide guidance for the actual assembly of the 1/8 VV sector. Finally, measurement and machining of the allowance are realized to solve the problem of numerical control machining of workpieces without a machining datum.

Position-Dependent Stability Prediction for Multi-Axis Milling of the Thin-Walled Component with a Curved Surface

Time-varying dynamic behaviors are essential to investigate the stability in the thin-walled workpiece milling process, which is usually affected by material removal and position-dependent characteristics of the workpiece along with the tool feed direction. To predict the milling stability with position-dependent, thin-walled component multi-axis milling, an improved structural dynamic modification method with variable mass is proposed in the paper. Firstly, the extraction of multi-axis milling material and the removal process of thin-walled parts with a complex curved surface and variable thickness is completed with CAM software. Then, the material removal of one cutting path as a modification of the structure is divided into multi-cutting steps with equal length to obtain the corrected FRFs in the machining process on the basis of the extended Sherman-Morrison-Woodbury formula. Furthermore, the dynamic characteristics of the initial un-machined workpiece and final machined workpiece are calculated by both experimental modal analysis and FEM. Finally, the multi-axis milling stability is predicted using the extended numerical integrated method, and an aero-engine blade is used to validate the accuracy and effectiveness of the proposed method for multi-axis milling molding parts.

Silver nanoparticle-based Tween 80 green cutting fluid (AgNP-GCF) assisted MQL machining - An attempt towards eco-friendly machining

In modern research, the instigation of eco-friendly and sustainable manufacturing options have drawn a great attention and become a global interest. Thus, usage of environmental pleasant cutting fluids and their least consumption in machining operation is a promising attempt towards cleaner and sustainable machining. In this work, experimental investigations during silver nanoparticle-based Tween 80 green cutting fluid (AgNP-GCF) assisted minimum quantity lubrication (MQL) machining were conducted. In the first stage of the work, synthesis and characterization of AgNPs was carried out. Secondly, novel AgNP-GCF has been developed by dispersing AgNPs in different proportions (0.2 ​wt %, 0.4 ​wt %, 0.6 ​wt % and 0.8 ​wt %) in the water based Tween 80 emulsifier oil. Lastly, the process performance of developed AgNP-GCF under different cutting speeds was investigated during MQL machining of Inconel 718. Process performance with regard to surface finish quality (surface roughness) of the machined workpiece material in five different machining environments such as dry machining (without cutting fluid), MQL machining with Tween 80 based cutting fluid (without AgNPs), MQL machining with 0.2 ​wt % AgNP-GCF, MQL machining with 0.4 ​wt % AgNP-GCF and MQL machining with 0.6 ​wt % AgNP-GCF was examined and results were related with each other. The substantial improvement in quality of machined workpiece material was observed during AgNP-GCF assisted MQL machining. Under tested cutting speeds, the 0.6 ​wt % AgNP-GCF assisted MQL machining was 55% more effective in reducing surface roughness when compared to dry machining and 26% more effective when compared to MQL machining with Tween 80 based cutting fluid (without AgNPs). The high quality of machined surface during MQL machining with AgNP-GCF was due to appreciable heat transfer through AgNPs and their strong inherent lubricant properties. This study is expected to promote the cleaner and more competent MQL machining through the application of developed eco-friendly cutting fluid. • Silver nanoparticles were added to water based Tween 80 emulsifier oil to prepare an eco-friendly cutting fluid. • Effect of developed cutting fluid on the machining surface finish quality was studied. • Silver nanoparticle-based cutting fluid assisted MQL machining was more effective in improving the surface quality on the machined surface. • Silver nanoparticle-based cutting fluid assisted MQL machining was effective in improving the machining performance. • Promotes cleaner and sustainable machining through the application of developed eco-friendly cutting fluid.

Dry turning of hard 2379 steel using a ZTA5Ce0.7La ceramic cutting insert: A study

The aim of this work is to evaluate the dry turning ability of zirconia toughened alumina reinforced with 5 wt.% CeO2 and 0.7 wt.% La2O3 (ZTA5Ce0.7La) ceramics as cutting insert in turning of 2379 steel with hardness of 43 HRC. Triangular cutting inserts were fabricated using this material composition via powder metallurgy route. Results of the cutting insert were measured based on the average width of flank wear and surface finish of machined workpiece. Results show that the tool was able to machine tool steel and good surface finishes were obtained for most of the cutting speeds used in the machining test, except for the highest cutting speed of 237.5 m/min. The longest life (12.5 minutes) of the cutting inserts according to the measured flank wear for the turning at cutting speed of 87.1 m/min with considerably good surface finish (Ra of 0.778 μm). Therefore, this ZTA5CeO0.7La cutting inserts is possible to be used as a successful dry turning process of 2379 steel.

An error compensation method based on machine vision for laser-processing systems with galvanometers

Laser-processing system plays an important role in modern processing. To improve the precision of a galvanometer laser-processing system, a novel compensation method based on machine vision is proposed. First, the various errors existing in the scanning process of the galvanometer system and the influence on the accuracy of the scanning system were analyzed. Second, processing a specific grid within the processing range of the laser-processing system, the machine vision method was employed to extract the skeleton image and obtain the sub-pixel coordinates of each grid corner point. By comparing them with their theoretical positions, the position and error of all corner points of the mesh were obtained. Finally, the position and error of the four corner points in the arbitrary grid region were analyzed by the weighted interpolation method, and the error value and compensation value of any point in the grid were derived, and an error compensation model was established to compensate the scanning system. To verify the effectiveness of the proposed compensation method, a compensation experiment was conducted, and the workpiece machining accuracy after compensation was improved. The method is simple in operation, offers good compensation effect, and has important theoretical significance and practical value for improving the precision of laser-processing systems.

Prediction of Surface Roughness of Turning Operations Using Computer Vision (Dept.M)

It is well known that measuring surface roughness is vital to quality control of the machined work piece. Recently, vision systems have been applied in industries for quality control and online inspection. Thus, measuring surface roughness using computer vision became easier and more flexible. Texture features are one of the most important techniques that have been utilized in industries in many applications. In this pap er, the texture features of the gray level co-occurrence matrix (GLCM) have been utilized to predict surface roughness of specimens machined by tuning operations. The relationship between GLCM texture features and surface roughness has been investigated to discover which texture features can be used to predict surface roughness. The correlation coefficient between each texture feature and the arithinetic average height (Ra) was calculated and discussed. The investigation showed that six texture features are highly correlated with Ra. Therefore, a software has been developed to predict surface roughness for specimens machined by turning operations using these texture features. The results showed that the maximum percentage of error between the actual Ra and the predicted Ra was about ±7%.

Prediction and control of surface roughness for the milling of Al/SiC metal matrix composites based on neural networks

In recent years, there has been a significant increase in the utilization of Al/SiC particulate composite materials in engineering fields, and the demand for accurate machining of such composite materials has grown accordingly. In this paper, a feed-forward multi-layered artificial neural network (ANN) roughness prediction model, using the Levenberg-Marquardt backpropagation training algorithm, is proposed to investigate the mathematical relationship between cutting parameters and average surface roughness during milling Al/SiC particulate composite materials. Milling experiments were conducted on a computer numerical control (CNC) milling machine with polycrystalline diamond (PCD) tools to acquire data for training the ANN roughness prediction model. Four cutting parameters were considered in these experiments: cutting speed, depth of cut, feed rate, and volume fraction of SiC. These parameters were also used as inputs for the ANN roughness prediction model. The output of the model was the average surface roughness of the machined workpiece. A successfully trained ANN roughness prediction model could predict the corresponding average surface roughness based on given cutting parameters, with a 2.08% mean relative error. Moreover, a roughness control model that could accurately determine the corresponding cutting parameters for a specific desired roughness with a 2.91% mean relative error was developed based on the ANN roughness prediction model. Finally, a more reliable and readable analysis of the influence of each parameter on roughness or the interaction between different parameters was conducted with the help of the ANN prediction model.

Study of phenomena responsible for part distortions when turning thin Inconel 718 workpieces

• A thorough in-situ experimental procedure to measure geometrical errors is presented. • Geometrical errors due to cutting forces and machining induced residual stresses are separated. • In the studied case, the impact of subsurface residual stresses on the total geometrical error is not negligible. • Tool wear dramatically increases the distortions linked to cutting forces and subsurface residual stresses. • The proportion of total errors linked to machining induced residual stresses increase with tool wear. Machining thin workpieces is a challenging task as geometrical errors may result from the combination of several phenomena. Among these, elastic workpiece deformation and machining induced residual stresses may be predominant sources due to low part stiffness. There is a lack of studies trying to quantify the influence of machining induced residual stresses on the total geometrical errors. A thorough experimental methodology is developed to quantify the influence of both phenomena separately by comparing the workpiece shape and dimensions, in-situ , before and after machining, using laser sensors. The proposed methodology can also be used to quantify the geometrical errors linked to clamping or stress rebalancing following material removal. The case study is the finish turning of thin Inconel 718 workpieces using carbide tools. In the studied case, machining induced residual stresses are responsible for 3–32 % of the total geometrical errors depending on tool wear and cutting parameters.

Discharge state identification and servo control method of high-speed reciprocating microwire-EDM

The electrical resistance of wire electrode increases with the decrease of the wire diameter. It is difficult to use the voltage threshold method to distinguish the spark and short-circuit states according to the discharge voltage, so it cannot meet the requirements of normal machining. In this study, a gap discharge state identification and servo control method based on discharge current are proposed in high-speed reciprocating microwire-EDM. The synchronous pulse can improve the stability of the system by reducing the disturbance of the discharge frequency and deionization. The experimental results show that a high wire speed is beneficial to the introduction of dielectric and the removal of erosion particles. When the target probability is set at 90%, the processing stability is higher. By using Φ 0.08 mm molybdenum wire electrode, the stable cutting of a 1250 height-diameter ratio (the ratio of cutting height to electrode wire diameter) workpiece is realized with an average cutting efficiency of 32.08 mm2/min. This study is a useful exploration of the machining of high height-diameter ratio workpieces by using a microwire electrode in high-speed wire-cut electrical discharge machining (HSWEDM).

The Optimal Processing Parameters of Radial Ultrasonic Rolling Electrochemical Micromachining-RSM Approach.

Radial ultrasonic rolling electrochemical micromachining (RUR-EMM) is a new method of electrochemical machining (ECM). By feeding small and rotating electrodes aided by ultrasonic rolling, an array of pits can be manufactured, which is called microstructures. However, there still exists the problem of choosing the optimal machining parameters to realize the workpiece machining with high quality and high efficiency. In the present study, response surface methodology (RSM) was proposed to optimize the machining parameters. Firstly, the performance criteria of the RUR-EMM are measured through investigating the effect of working parameters, such as applied voltage, electrode rotation speed, pulse frequency and interelectrode gap (IEG), on material removal amount (MRA) and surface roughness (Ra). Then, the experimental results are statistically analyzed and modeled through RSM. The regression model adequacies are checked using the analysis of variance. Furthermore, the optimal combination of these parameters has been evaluated and verified by experiment to maximize MRA and minimize Ra. The results show that each parameter has a similar and non-linear influence on the MRA and Ra. Specifically, with the increase of each parameter, MRA increases first and decreases when the parameters reach a certain value. On the contrary, Ra decreases first and then increases. Under the combined effect of these parameters, the productivity is improved. The experimental value of MRA and Ra is 0.06006 mm2 and 51.1 nm, which were 0.8% and 2.4% different from the predicted values.

An investigation into tool dynamics adaptation for chatter stability enhancement in the turning of flexible workpieces

It seems a universally accepted doctrine that chatter resistance of a machining system can be improved with increasing stiffness of its components. However, the viewpoint that the tool stiffness reduction would be beneficial to cutting stability of flexible components has been demonstrated by the compliant tool-workpiece chatter model. This paper presents a comprehensive investigation of the dynamic interaction between the tool and the workpiece during turning operations and its effect on the cutting stability. Following the formulation of the chatter model, the effect of the coupling dynamics of the cutting system on the limiting depth of cut (doc), a conservative but reliable indicator for evaluating the stability level of the machining process, is highlighted. It is shown that stability can be enhanced by judicious increase of the tool flexibility and/or the workpiece damping. Also, an inflexion point generally exists on the cutting position-dependent limiting doc stability curve, revealing that the stability appears to be unchanged once the stiffness of the tool or workpiece is increased to a certain degree. As a result, the analysis results lay the foundation of a tool dynamics adaptation (TDA) approach to machining chatter control. It suggests an adaptive adjustment of the tool dynamics to the machined workpiece to enhance stability. The proposed approach was validated through turning experiments, in which the tool shank was installed parallel to the length of the flexible workpiece. The experimental results have shown an effective extension of the chatter-free cutting margin when tuning dynamics of the compliant tool-workpiece system. Given the reality that there is no absolutely rigid workpiece or tool in industrial applications, the proposed chatter control strategy can be adopted as a generic approach for the turning or boring processes.

Near-Net-Shape Trimming Process by Abrasive Water Jet Cutting of High-Performance Workpieces for the Aerospace Industry

High-performance materials offer enormous potential for increasing the efficiency of many complex and highly stressed systems in the aerospace industry. However, due to their special material properties, most of these materials are very difficult to machine using conventional machining processes such as turning, milling and drilling. In comparison, water jet cutting technology offers all the prerequisites to bring high-performance materials to their final contour and to efficiently realize a large portion of the material removal. Because of the complex geometry of 3D components used in the aerospace industry, a further development of existing system technology as well as the generation of cutting paths, which are usually designed for pure 2D machining, is required. The aim of the study is the implementation of an automated pre-contouring for difficult to machine materials using abrasive water jet cutting for industrial 3D applications. This is achieved by using an innovative workpiece clamping as well as a new cutting technology, the trimming, in order to reduce the costs of the pre-contouring process as well as the time and resource consumption of the entire process chain. During trimming, a continuous cut takes place and the semi-finished product is brought closer and closer to the required component geometry by cutting off the outer material areas. For this purpose, tests were carried out on workpieces made of stainless steel X5CrNi18 (EN 1.4301) with cutting conditions that are demanding for the abrasive water jet cutting process, such as high cutting depths with simultaneously low cutting angles. It was possible to use these findings to extend existing material models and thus ensure an error-free path generation for cutting processes. The investigations are the basis for the future use of waterjet cutting for near-net-shape machining of workpieces with complex 3D geometry. The experiments showed promising results in terms of the economic efficiency of the trimming process and provide a basis for subsequent investigations with difficult-to-machine workpieces for the aerospace industry.

Technological quality maintenance of finishing robotic machining in mechanical engineering

Give consideration to development of robotic systems in modern mechanical engineering, as well as the advantages of their introduction into production to perform mechanical machining of work-piece. Schemes of operations using robots are given, as well as the main types of robotic systems used in mechanical engineering. Description provided to the experimental setup for finishing robotic machining. The results of field research to find the optimal cutting conditions that provide the required surface quality after processing are described.

Performance of laser surface textured cemented carbide tools during abrasive machining: Coating effects, surface integrity assessment and wear characterization

Laser surface texturing (LST) and coating deposition are implemented on cemented carbide (WC-CoNi) tools to extent their application in abrasive-like machining processes. The topographic features of a conventional cubic boron nitride based honing stone are achieved by LST, whereas wear resistance is enhanced by deposition of a ceramic layer. Three tool types are considered here: uncoated and coated LST WC-CoNi tools, besides a honing stone used as reference. They are tested under abrasive-like cutting conditions using an in-house workbench and a workpiece made of 20MnCr5 steel. Wear resistance and mechanisms as well as surface integrity of the tools after cutting tests are evaluated. It is found that LST cemented carbide tools achieve similar material removal effectiveness to the honing stone. Furthermore, coated LST tool exhibits a better cutting capacity, in terms of machined workpieces with smoother surfaces and enhanced wear resistance. However, the cutting process using cemented carbide tools is not as stable as the one developed employing the honing stone. The different response is related to the tribological conditions of the cutting edges of the laser-shaped pyramids. Damage within constitutive microstructural phases is clearly reduced for the coated condition, although it is still directly related to geometrical complexity of the pyramids.

DECODING OF THE RELATIONSHIP BETWEEN COMPLEX STRUCTURES OF MACHINED SURFACE AND TOOL WEAR IN MILLING OPERATION

Surface finish of machined workpiece is one of the factors to evaluate the performance of machining operations. There are different factors such as machining parameters that affect the surface finish of machined workpiece. Tool wear is an unwanted machining issue that highly affects the surface finish of machined workpiece. In a similar way, different parameters (e.g. cutting speed, feed rate and depth of cut) also affect tool wear. In this research, we investigated how the complex structure of machined workpiece is related to the complex structure of tool wear. For this purpose, we benefited from the fractal analysis. The experiments were conducted based on the variations of machining parameters (depth of cut, feed rate and spindle speed), and accordingly the fractal dimension of machined surface was analyzed versus the fractal dimension of tool wear. Based on the obtained results, the complexity of machined surface is related to the complexity of tool wear. Fractal analysis could be applied to other machining operations to analyze the complex structures of machined surface and tool and potentially make a relationship between them.

Non-Conventional Technique of Machining and Metallization of Polymer Components

Background: Machining and metal coating of plastics are essential requirements as plastics are overtaking other engineering materials nowadays. Metallization improves product life as well as enhances its surface and mechanical properties. The machining (i.e., cutting, drilling, boring) of plastic parts with conventional processes is difficult as the dimensional accuracy and surface finish cannot be obtained from existing methods or/and needs multiple operations to acquire the surface finish needed. The coating of plastic materials is also a complex method using chemicals and electricity. An innovative method of coating and machining on plastic components has been demonstrated, which would be beneficial for potential researchers. A detailed analysis of previous patents and techniques has been performed based on which an advanced apparatus has been proposed. Objective: The objective of this study was to develop an apparatus based on non-conventional machining techniques. Moreover, the apparatus would be capable of plating metal layer on polymers using chemicals and fine metal particles. An in-depth analysis of previous patents used for the same application has been performed and based on the limitations of already existing techniques. Methods: An apparatus for machining and metal coating of polymers utilizes compressed air at high pressure mixed with chemical vapors. Before compression, the air is filtered to remove the impurities and moisture. Afterwards, heated chemical vapors are mixed with air in a specific proportion for machining of plastic parts. A jet of air and chemical vapours impinges on work material, which would perform machining in two steps. Initially, the chemical vapours would dissolve plastic material, which would instantly melt and starts flowing. Afterwards, the air jet would remove the excess plastic material due to high pressure. On the other hand, metallization can also be performed using different chemicals in proper proportion. Results: The apparatus makes it easy for machining and metalizing the ABS or plastic parts as the process is performed on one apparatus simultaneously one after the other. The high speed jet of acetone vapors has a greater tendency to perform various machining operations like cutting, drilling, boring of ABS parts. These vapours, when mixed with pressurized air, enhance the capability of machining the workpieces. And the metallization of plastic parts provides luster and surface finish to the workpiece. Conclusion: The present invention is to provide an apparatus for effectively plating or coating the machined workpieces. Moreover, the present work provides detailing of an apparatus for improving the mechanical strength, hardness and surface finish of the machined workpiece. In addition to this, the proposed apparatus is enabled to make strong bonding between metal particles and plastics.

Evaluation of a cooled wheel cleaning jet in minimum quantity lubrication grinding process

The application of the minimum quantity lubrication (MQL) technique in grinding processes is still limited due to the frequent occurrence of overheating and wheel clogging. In this context, this research evaluates a cooled wheel cleaning jet (CWCJ) under different temperatures, applied simultaneously to MQL in the cylindrical grinding of AISI 4340 quenched and tempered steel, using a CBN wheel. For comparison, tests with the MQL, MQL + WCJ, and conventional techniques were also performed. Surface roughness, microhardness, and roundness deviation of the workpieces, wheel wear, and grinding power were the assessed output parameters. The machined workpieces were evaluated by optical, confocal, and scanning electron microscopies. The MQL + WCJ outperformed MQL and MQL + WCJ in all the tested conditions. The application of the cooled wheel cleaning jet reduced by up to 79% the surface roughness, 82% the wheel wear, 76% the roundness deviation, and 37% the grinding power, regarding MQL and MQL + WCJ techniques, contributing towards a sustainable and high-quality grinding process.

A Critical Reanalysis of Uncontrollable Washboarding Phenomenon in Metal Band Sawing.

The article analyzes the cutting process of hard bars. Investigations conducted in industrial conditions demonstrated the presence of surface errors in the machined workpieces in the form of washboard patterns. The purpose of this study was to analyze the results of cutting on band sawing machines with different band saw blades. The cutting processes were conducted on three different horizontal band sawing machine types. Analyzed material was an alloy steel Ø40 mm rod with a hardened surface covered with a thin layer of chromium. The hardness of the outer layer was 547 HV with a core hardness of 180 HV. The surface topography measurements of the processed workpieces were carried out with the 3D Optical Profiler, which supplied information on the irregularities of the processed material texture. In each of the analyzed cases, a corrugated surface was obtained after sawing, which is the effect of the occurrence of the washboarding phenomenon, despite the fact that the teeth of each band saw had variable pitches. The washboarding phenomenon when cutting rods with hard surfaces is caused by the phenomenon of wave regeneration. Despite the use of variable pitch saw blades, the cutting process results in rippling of the sawn surface, which is caused by the high hardness of the outer layer of the workpiece, as well as by the type of tool with spring setting of teeth.

Управляемые шпиндельные опоры как инструмент обеспечения качества обработки

The purpose of the work is to provide conditions for machined workpiece surface quality control based on the use of gas-magnetic supports in machine-tool systems (on example of the 3K227A internal grinding machine). To model the trajectory of tool and workpiece mutual movement the methods of nonlinear dynamics are used. The literature data on the problem are analyzed and experimental studies are carried out. Based on the considered issues of controlling the dynamic stability of technological systems under machining by means of contactless controlled gas-magnetic supports of spindle units, a scheme for adaptive control of the machine-tool system is proposed. It allows in many respects to eliminate external mechanical effects on the technological system, internal vibrations caused by drives and moving parts, as well as to compensate temperature deformations of the spindle unit frame and body. An adaptive control system based on gas-magnetic supports of the spindle assembly and the workpiece, as well as the control systems of the position of workpiece and tool (on example of 3K227A internal grinding machine) are demonstrated in action. The gas-magnetic support control system developed at Komsomolsk-na-Amure State Technical University makes it possible to set the position of the rotor axis with the accuracy of 0.1 microns. The study results obtained lead to the conclusion that the control of two adaptive links on the gas-magnetic supports, i.e., the spindle assembly of the tool and the spindle assembly of the workpiece, allows to achieve a rotation accuracy of up to 0.2 microns. The methods of nonlinear dynamics make it possible to construct an attractor (trajectory) of the tool tip movement in the real time, which provides a possibility to affect the input parameters of the machining process and thereby to control the output parameters. In addition to this, the control system of machine-tool system dynamic stability is applicable to other processing types as well, including edge cutting machining.