On-Line Monitoring of End Milling Forces Using a Thin Film Based Wireless Sensor Module

2010 ◽  
Author(s):  
Lei Ma ◽  
Shreyes N. Melkote ◽  
John B. Morehouse ◽  
James B. Castle ◽  
James W. Fonda
Keyword(s):  
Thin Film ◽  
End Milling ◽  
Beam Theory ◽  
Dynamic Strain ◽  
Sensor Signal ◽  
Sensor Material ◽  
Slot Milling ◽  
Feed Force ◽  
Sensor Module ◽  
Milling Forces

A sensor module that integrates a thin film PVDF piezoelectric strain sensor and a wireless data processing/transmitting platform has been designed and implemented for wireless monitoring of the feed force in the slot end milling process. The module, which is mounted on the tool shank, measures the dynamic strain produced in the tool and transmits data wirelessly to the receiver connected to a data acquisition computer. A first principles model based on the Euler-Bernoulli beam theory and constitutive equations of the piezoelectric sensor material is used to transform the wirelessly obtained data into the feed force acting on the tool in a slot milling operation. The wireless PVDF sensor signal is found to compare well with the expected (or theoretical) sensor signal computed from the measured feed force in slot milling experiments.

Thin-Film PVDF Sensor Based Monitoring of Cutting Forces in Peripheral End Milling

2012 ◽  
Author(s):  
Lei Ma ◽  
Shreyes N. Melkote ◽  
John B. Morehouse ◽  
James B. Castle ◽  
James W. Fonda ◽  
...  
Keyword(s):  
Thin Film ◽  
Polyvinylidene Fluoride ◽  
End Milling ◽  
Beam Theory ◽  
Dynamic Strain ◽  
Data Logging ◽  
Sensor Material ◽  
Sensor Module ◽  
Sensor Signals

A sensor module that integrates a thin film Polyvinylidene Fluoride (PVDF) piezoelectric strain sensor and an in situ data logging platform has been designed and implemented for monitoring of feed and transverse forces in the peripheral end milling process. The module, which is mounted on the tool shank, measures the dynamic strain(s) produced in the tool and logs the data into an on-board card for later retrieval. The close proximity between the signal source and the PVDF sensor(s) minimizes the attenuation and distortion of the signal along the transmitting path and provides high-fidelity signals. It also facilitates the employment of a first principles model based on Euler-Bernoulli beam theory and the constitutive equations of the piezoelectric sensor material to relate the in situ measured PVDF sensor signals to the feed and transverse forces acting on the tool. The PVDF sensor signals are found to compare well with the force signals measured by a platform type piezoelectric force dynamometer in peripheral end milling experiments.

Thin-Film PVDF Sensor-Based Monitoring of Cutting Forces in Peripheral End Milling

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Lei Ma ◽  
Shreyes N. Melkote ◽  
John B. Morehouse ◽  
James B. Castle ◽  
James W. Fonda ◽  
...  
Keyword(s):  
Thin Film ◽  
Polyvinylidene Fluoride ◽  
End Milling ◽  
Beam Theory ◽  
Dynamic Strain ◽  
Data Logging ◽  
Sensor Material ◽  
Sensor Module ◽  
Sensor Signals

A sensor module that integrates a thin film polyvinylidene fluoride (PVDF) piezoelectric strain sensor and an in situ data logging platform has been designed and implemented for monitoring of the feed and transverse forces in the peripheral end milling process. The module, which is mounted on the tool shank, measures the dynamic strain(s) produced in the tool and logs the data into an on-board card for later retrieval. The close proximity between the signal source and the PVDF sensor(s) minimizes the attenuation and distortion of the signal along the transmission path and provides high-fidelity signals. It also facilitates the employment of a first principles model based on the Euler–Bernoulli beam theory and constitutive equations of the piezoelectric sensor material to relate the in situ measured PVDF sensor signals to the feed and transverse forces acting on the tool. The PVDF sensor signals are found to compare well with the force signals measured by a platform-type piezoelectric force dynamometer in peripheral end milling experiments.

A new electric power sensor module using magnetoresistive thin film

1989 ◽  
Vol 25 (5) ◽  
pp. 3821-3823
Author(s):  
H. Yoda ◽  
S. Kurashima ◽  
M. Endoh ◽  
N. Wakatsuki
Keyword(s):  
Thin Film ◽  
Electric Power ◽  
Sensor Module ◽  
Power Sensor

FRACTAL-BASED ANALYSIS OF THE VARIATIONS OF CUTTING FORCES ALONG DIFFERENT AXES IN END MILLING OPERATION

Fractals ◽  
2018 ◽  
Vol 26 (06) ◽  
pp. 1850089 ◽  
Author(s):  
HAMIDREZA NAMAZI ◽  
ALI AKHAVAN FARID ◽  
TECK SENG CHANG
Keyword(s):  
Fractal Dimension ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Fractal Theory ◽  
Radial Force ◽  
Machining Conditions ◽  
Feed Force ◽  
Milling Operation ◽  
Force Signal

Analysis of cutting forces in machining operation is an important issue. The cutting force changes randomly in milling operation where it makes a signal by plotting over time span. An important type of analysis belongs to the study of how cutting forces change along different axes. Since cutting force has fractal characteristics, in this paper for the first time we analyze the variations of complexity of cutting force signal along different axes using fractal theory. For this purpose, we consider two cutting depths and do milling operation in dry and wet machining conditions. The obtained cutting force time series was analyzed by computing the fractal dimension. The result showed that in both wet and dry machining conditions, the feed force (along [Formula: see text]-axis) has greater fractal dimension than radial force (along [Formula: see text]-axis). In addition, the radial force (along [Formula: see text]-axis) has greater fractal dimension than thrust force (along [Formula: see text]-axis). The method of analysis that was used in this research can be applied to other machining operations to study the variations of fractal structure of cutting force signal along different axes.

Mechanical deflection of cantilever microbeams: A new technique for testing the mechanical properties of thin films

1988 ◽  
Vol 3 (5) ◽  
pp. 931-942 ◽  
Author(s):  
T. P. Weihs ◽  
S. Hong ◽  
J. C. Bravman ◽  
W. D. Nix
Keyword(s):  
Thin Film ◽  
Thin Films ◽  
Mechanical Properties ◽  
Single Layer ◽  
Beam Theory ◽  
New Technique ◽  
Young’S Moduli ◽  
Silicon Micromachining ◽  
A New Technique

The mechanical deflection of cantilever microbeams is presented as a new technique for testing the mechanical properties of thin films. Single-layer microbeams of Au and SiO2 have been fabricated using conventional silicon micromachining techniques. Typical thickness, width, and length dimensions of the beams are 1.0,20, and 30 μm, respectively. The beams are mechanically deflected by a Nanoindenter, a submicron indentation instrument that continuously monitors load and deflection. Using simple beam theory and the load-deflection data, the Young's moduli and the yield strengths of thin-film materials that comprise the beams are determined. The measured mechanical properties are compared to those obtained by indenting similar thin films supported by their substrate.

Doped β-FeSi/sub 2/ as thin film thermoelement sensor material

2002 ◽  
Author(s):  
J. Schumann ◽  
H. Griessmann ◽  
A. Heinrich
Keyword(s):  
Thin Film ◽  
Sensor Material

Liquid-Phase Co-Exfoliated Graphene/MoS2 Nanocomposite for Methanol Gas Sensing

2015 ◽  
Vol 15 (10) ◽  
pp. 8004-8009 ◽  
Author(s):  
Shao-Lin Zhang ◽  
Hongyan Yue ◽  
Xishuang Liang ◽  
Woo-Chul Yang
Keyword(s):  
Thin Film ◽  
Gas Sensing ◽  
Synergetic Effect ◽  
Film Sensor ◽  
Thin Film Sensor ◽  
Sensor Material ◽  
Enhanced Sensitivity ◽  
Distinct Structure ◽  
Nanocomposite Sensor ◽  
Sensing Performance

We developed an efficient method to co-exfoliate graphite and MoS2 to fabricate graphene/MoS2 nanocomposite. The size, morphology, and crystal structure of the graphene/MoS2 nanocomposite were carefully examined. The as-prepared graphene/MoS2 nanocomposite was fabricated into thin film sensor by a facile drop casting method and tested with methanol gas in various concentrations. The sensitivity, response time, and repeatability of the graphene/MoS2 nanocomposite sensor towards methanol gas were systematically investigated. A pure MoS2− based thin film sensor was also prepared and compared with the nanocomposite sensor to better understand the synergetic effect in the sensing performance. Our research demonstrated that compositing MoS2 with graphene could overcome the shortcoming of MoS2 as a sensor material and bring in a promising gas-sensing performance with a quicker response/recovery time and an enhanced sensitivity. Moreover, this composited material with a distinct structure and an excellent electronic property is expected to have potential application in various fields, such as optoelectronic.

A Simulation Study on the End Milling Operation with Multiple Process Steps of Aeronautical Frame Monolithic Components

2011 ◽  
Vol 66-68 ◽  
pp. 569-572
Author(s):  
Hai Chao Ye ◽  
Guo Hua Qin ◽  
Cong Kang Wang ◽  
Dong Lu
Keyword(s):  
End Milling ◽  
Machining Process ◽  
Deformation Analysis ◽  
Tool Paths ◽  
Milling Operation ◽  
Multiple Process ◽  
Monolithic Components ◽  
Milling Forces ◽  
The Given

Machining deformation has always been a bottleneck issue in the manufacturing field of aeronautical monolithic components. On the base of finite element method, the effect of the process steps and tool paths on the workpiece stiffness and the redistribution of residual stress in the machining process of aeronautical frame monolithic component was investigated under the given fixturing scheme. Thus, the prediction of the workpiece deformation can be carried out in reason. The proposed simulation approach to deformation analysis can be used to observe the true characteristic of milling forces and machining deformations. Therefore, the proposed method can supply the theoretical basis for the determination of the optimal process parameters.

A HIGHER FIDELITY MODELING OF THE CUTTING EDGE OF BALL-END MILLING TOOL

2011 ◽  
Vol 10 (01) ◽  
pp. 101-108 ◽  
Author(s):  
XIULIN SUI ◽  
IMRE HORVATH ◽  
JIATAI ZHANG ◽  
PING ZHANG
Keyword(s):  
End Milling ◽  
Milling Process ◽  
Cutting Edge ◽  
Ball End Milling ◽  
Machining Conditions ◽  
Milling Tool ◽  
Efficient Planning ◽  
Pilot Implementation ◽  
Physical Changes ◽  
Milling Forces

Ball-end milling tools have been widely used in machining of complex freeform surfaces. The precision and efficiency of ball-end milling process can be improved by an accurate modeling of the tools, the tools' paths and the machining conditions. However, only rough geometric models have been applied so far, which do not consider the machining conditions and the physical changes. To achieve the best results, an accurate modeling of the cutting edge and the physical behavior of the entire cutter is needed. This paper proposes an articulated model that enumerates both the geometric characteristics and the physical effects acting on the cutting edge-segment of a ball-end milling cutter. The model considers the deformations caused by the milling forces, vibration, spindle eccentricity, together with thermal deformation and wear of the cutter. The mathematical description of the behavior has been transferred into a computational model. The pilot implementation has been tested in a practical application. The first findings show that the proposed theoretical model and implementation provide sufficiently precise information about the behavior of the cutter in virtual simulations; hence it can be the basis of a fully fledged and more efficient planning of milling processes.

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