Cutting force validation and volumetric errors compensation of thin workpieces with sensory tool holder

A calculation scheme to gain the relationship between the thickness of shrink-fit holder and thermodynamic properties. Based on the theoretical analysis of fitting molder between shrink-fit holder and tool, then the thermodynamic properties of the shrink-fit holder and cutting tool such as contact pressure, equivalent stress and deformation are analyzed at different thickness of shrink-fit holder in static, under cutting force and inducting heating by using the finite element software ANSYS. The results show that the total contact pressure and maximum equivalent stress increased and the minimum thermal displacement difference decreased with the increase of holder thickness. Under the action of cutting force, the contact stress on the tool holder no longer uniformed and the maximum contact stress significantly increased, cutting tool also deformed. Finally a method to determine the reasonable holder thickness is given and it has a practical guiding significance for the design and selection of the shrink-fit tool holder.

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Chatter Stability Prediction Method of the Spindle-Tool Holder-Tool System with Interface Contact Characteristics

Mathematical Problems in Engineering ◽

10.1155/2020/7121328 ◽

2020 ◽

Vol 2020 ◽

pp. 1-15

Author(s):

Li Cui ◽

Yin Su

Keyword(s):

Cutting Force ◽

Prediction Method ◽

Chatter Stability ◽

Chatter Vibration ◽

Cutting Depth ◽

Milling Stability ◽

Tool Holder ◽

Interface Dynamic ◽

Interface Contact ◽

Chatter Stability Prediction

To predict chatter stability and suppress chatter vibration, a chatter stability prediction method for the spindle-tool holder-tool system with interface contact characteristics is constructed. A five-DOF model is constructed to determine the spindle-bearing interface dynamic contact stiffness considering the coupling effect of spindle and bearing. A fractal multiscale tool holder-spindle interface dynamic stiffness model is proposed considering time-varying cutting force. The fractal dimensions and cutting force coefficient parameters are identified from the power spectrum experiments and cutting force tests. The cutting force is solved according to the milling stability model. Dynamic model of the spindle-tool holder-tool system is found by the finite element method. Based on extended Floquet theory, chatter stability of the spindle system is studied. Effect of interface parameters, radial cutting depth, and feed rate on milling stability is researched. Milling force tests and milling stability tests are performed in order to verify the reliability of the method. Results find that the increase of front bearing preload and spindle-tool holder’s interference fit are effective to improve the milling stability. The optimal feed rate and the critical radial cutting depth are found. The model proposed in this paper can be used as an instruction for predicting and suppressing the chatter vibration and optimizing cutting parameters and also is helpful for designing the spindle-tool holder-tool system.

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Wireless tool holder sensor design for cutting force measurement applied to chatter detection

2016 IEEE Region 10 Conference (TENCON) ◽

10.1109/tencon.2016.7848340 ◽

2016 ◽

Cited By ~ 1

Author(s):

D.A. Reyes Uquillas ◽

T. Hsiao

Keyword(s):

Cutting Force ◽

Force Measurement ◽

Sensor Design ◽

Chatter Detection ◽

Tool Holder ◽

Cutting Force Measurement

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Development and testing of an integrated smart tool holder for four-component cutting force measurement

Mechanical Systems and Signal Processing ◽

10.1016/j.ymssp.2017.01.038 ◽

2017 ◽

Vol 93 ◽

pp. 225-240 ◽

Cited By ~ 21

Author(s):

Zhengyou Xie ◽

Yong Lu ◽

Jianguang Li

Keyword(s):

Cutting Force ◽

Force Measurement ◽

Tool Holder ◽

Cutting Force Measurement

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A Smart Tool Holder Calibrated by Machine Learning for Measuring Cutting Force in Fine Turning and Its Application to the Specific Cutting Force of Low Carbon Steel S15C

Machines ◽

10.3390/machines9090190 ◽

2021 ◽

Vol 9 (9) ◽

pp. 190

Author(s):

Liang-Wei Tseng ◽

Teng-Shan Hu ◽

Yuh-Chung Hu

Keyword(s):

Carbon Steel ◽

Cutting Force ◽

Low Carbon Steel ◽

Force Sensor ◽

Machining Process ◽

Force Model ◽

Low Carbon ◽

Specific Cutting Force ◽

Tool Holder ◽

Fine Turning

Real-time monitoring of the cutting force in the machining process is critical for improving machining accuracy, optimizing the machining process, and optimizing tool lifetime; however, the dynamometers are too expensive to be widely used by machine tool users. Therefore, this paper presents a simple and cheap apparatus—a smart tool holder—to measure the cutting force of turning tools in the finishing turning. The apparatus does not change the structure of the turning tool. It consists of a tool holder and a piezoresistive force sensor foil, and transmits the signal through Bluetooth wireless communication. Instead of dealing with the circuit hardware, this paper uses the Artificial Neural Network (ANN) model to successfully calibrate the warm-up shift problem of the piezoresistive force sensor. Such a software method is simple, and considerably cheaper than the hardware method. For the force measurement capability of the smart tool holder, the cross-interference between orthogonal forces are very small and thus can be ignored. The force reading of the smart tool holder possesses high repeatability for the same turning parameters and high accuracy within the experiment groups. The authors apply the smart tool holder to cut the low carbon steel S15C, and to determine its specific cutting force in fine turning. The resulting fine turning force model agrees very well with the measurement. Its mean absolute deviation is 3.87% and its standard deviation is 1.55%, which reveals that the accuracy and precision of the smart tool holder and the fine turning force model are both good.

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Development of Shrinking Tool Holder Utilizing of Shape Memory Alloy

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.291-292.525 ◽

2005 ◽

Vol 291-292 ◽

pp. 525-530 ◽

Cited By ~ 1

Author(s):

Koichi Kitajima ◽

H. Sogabe ◽

M. Hiromi

Keyword(s):

Shape Memory Alloy ◽

Shape Memory ◽

Cutting Force ◽

Tool Steel ◽

Ti Alloy ◽

Tool Holder ◽

Alloy Tool

This paper investigates how to use shape memory alloy (SMA, Ni-Ti alloy) as a method of chucking parts. It is because tool holder can be simplified and miniaturized. SMA cannot be utilized as chucking tool because it is one-way direction, but it is possible to shrink and release a tool by changing temperature in case SMA is made of combing cylinder with alloy tool steel (SKD61 in JIS). In this report, prototype shrinking tool holder that used combing cylinder with SMA was developed and tried milling processes. As a result, it is clear that combing cylinder with SMA can endure cutting force.

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Theoretical investigation on nonlinear dynamic characteristic of spindle system

Advanced Composites Letters ◽

10.1177/2633366x20911665 ◽

2020 ◽

Vol 29 ◽

pp. 2633366X2091166

Author(s):

Xiangsheng Gao ◽

Zeyun Qin ◽

Min Wang ◽

Yuming Hao ◽

Ziyu Liu

Keyword(s):

Dynamic Response ◽

Cutting Force ◽

Dynamic Characteristic ◽

Rotational Speed ◽

High Speed ◽

Engineering Practice ◽

Nonlinear Stiffness ◽

Spindle System ◽

Tool Holder ◽

Radial Gap

Radial gap will occur at the spindle–tool holder interface when the spindle rotates at high speed. Therefore, the radial gap will lead to the nonlinear stiffness at the spindle–tool holder connection, and it will have effects on dynamic characteristic of spindle system. In this research, classic elastic theory is adopted to evaluate the nonlinear stiffness at spindle–tool holder interface. Dynamic model of spindle system is established considering the nonlinear stiffness at spindle–tool holder interface. The fourth-order Runge–Kutta method is applied to solve dynamic response of the spindle system. On that basis, effects of drawbar force on dynamic characteristic of the system are investigated. Considering the cutting force, effects of rotational speed on dynamic response of cutter tip are also discussed. The numerical results show that the drawbar force has effects on vibration mode of cutter tip. Chaotic motion will not occur within the range concerned in engineering practice. Considering the cutting force, the motion of cutter tip turns to be chaotic. The proper rotational speed and drawbar force should be chosen to ensure a stable cutting according to the response of cutter tip.

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