Erfahrungen mit alternativen Kraftmessungen/Experiences with alternative force measurements - Comparing sensor-integrated toolholders to traditional piezo-based measurement technology

2020 ◽  
Vol 110 (01-02) ◽  
pp. 24-31
Author(s):  
Patrick Georgi ◽  
Ssrah Eschelbacher ◽  
Thomas Stehle ◽  
Hans-Christian Möhring
Keyword(s):  
Cutting Force ◽  
Force Measurement ◽  
Milling Process ◽  
The Other ◽  
Strain Gauges ◽  
Measurement Technology ◽  
Optimal Parameters ◽  
Force Measurements ◽  
Measuring Systems ◽  
The One

Die Prozessüberwachung spielt in der Zerspanung eine immer wichtiger werdende Rolle. So können zum Beispiel mittels Zerspankraftmessungen ökonomisch optimierte Parameter in Zerspanprozessen gefunden werden, die zu einer Verbesserung der Auslastung von Werkzeug und Maschine führen. Des Weiteren kann über die Zerspankraft auf den aktuellen Verschleißzustand der Werkzeuge im Prozess sowie auf die jeweils erreichbare Bearbeitungsgenauigkeit zurückgeschlossen werden. Für Zerspankraftmessungen gibt es eine Vielzahl an zur Verfügung stehenden Kraftmesssystemen; zum einen traditionelle Messtechnik auf Basis von Piezosensoren zur Kraftmessung und zum anderen Kraftmesstechnik auf der Basis von Dehnmessstreifen (DMS). Dieser Beitrag untersucht die Kraftaufnahme bei Fräs- und Bohrprozessen, bei denen beide Kraftmesssysteme simultan eingesetzt wurden.   Process monitoring plays an increasingly important role in machining. For example, through cutting force measurements, it is possible to find economically optimal parameters in the milling process, which lead to an improvement in the utilization of the tool and the machine. Furthermore, the cutting force can be used to deduce the state of wear of the tools in the process. There are varieties of available force measuring systems for this purpose; on the one hand, traditional measuring technology based on piezo sensors for force measurement and the other force measuring technology based on strain gauges (strain gauges). This article examines the force absorption in milling and drilling processes where both force-measuring systems were used simultaneously.

scholarly journals Cutting Forces Measurement for Milling Process by Using Working Tables with Integrated PVDF Thin-Film Sensors

Sensors ◽  
2018 ◽  
Vol 18 (11) ◽  
pp. 4031 ◽  
Author(s):  
Ming Luo ◽  
Zenghui Chong ◽  
Dongsheng Liu
Keyword(s):  
Thin Film ◽  
Cutting Force ◽  
Cutting Forces ◽  
Polyvinylidene Fluoride ◽  
Force Measurement ◽  
Milling Process ◽  
Machining Process ◽  
Signal Spectrum ◽  
Milling Force ◽  
Thin Film Sensors

In the milling process, cutting forces contain key information about the machining process status in terms of workpiece quality and tool condition. On-line cutting force measurement is key for machining condition monitoring and machined surface quality assurance. This paper presents a novel instrumented working table with integrated polyvinylidene fluoride (PVDF) thin-film sensors, thus enabling the dynamic milling force measurement with compact structures. To achieve this, PVDF thin-film sensors are integrated into the working table to sense forces in different directions and the dedicated cutting force decoupling model is derived. A prototype instrumented working table is developed and validated. The validation demonstrates that profiles of the forces measured from the developed instrumented working table prototype and the dynamometer match well. Furthermore, the milling experiment results convey that the instrumented working table prototype could also identify the tool runout due to tool manufacturing or assembly errors, and the force signal spectrum analysis indicates that the developed working table can capture the tool passing frequency correctly, therefore, is suitable for the milling force measurement.

Microfabrication and Characterization of Tool Embedded Ni-Chrome Thin Film Micro-Sensors for Cutting Force Measurement

2016 ◽  
Vol 693 ◽  
pp. 1074-1081
Author(s):  
Yun Ping Cheng ◽  
Wen Ge Wu ◽  
Xiao Jun Du ◽  
Chun Hua An
Keyword(s):  
Thin Film ◽  
Cutting Force ◽  
Force Measurement ◽  
Strain Gauges ◽  
Film Sensor ◽  
Thin Film Sensor ◽  
Nickel Chromium ◽  
Cutting Force Measurement ◽  
Digital Microscope ◽  
Machining Operations

This paper investigated the fabrication and design of embedded Ni-chrome thin-film strain gauges as micro-sensors in tool holders to measure the cutting force in machining operations. A Ni-chrome thin film as piezoresistive material sensor device is embedded within a substrate structure through brazing bonding process, which consists of a Ti6Al4V substrate, a Nickel-chromium thin film sensor and an Alumina insulating layer. The thin-films were characterized by 3D Super Depth Digital Microscope, SEM/EDS, Stylus profiler, to study microstructure, material composition, thickness and sheet resistance respectively. The thin-film strain gauges are calibrated in a cantilever beam setup. Accordingly, in-process cutting force measurement systems are established. The results showed that the thin-film sensor had good linearity and more elaborate structure and superior properties.

NC Lathe Cutting Force Measurement Method and Application of Online

2012 ◽  
Vol 529 ◽  
pp. 318-321
Author(s):  
Yong Qing Ma ◽  
Ming Qing Wu
Keyword(s):  
Data Collection ◽  
Cutting Force ◽  
Measurement Method ◽  
Technology Development ◽  
Force Measurement ◽  
Measurement Instrument ◽  
Measurement Technology ◽  
Cutting Force Measurement ◽  
Analysis System ◽  
Set Up

Cutting force measurement system by force measurement instrument, general data collection system and PC of three parts. The size of the cutting force general use have experimental results set up experience formula. Introduces two kinds of accurate measurement method of cutting force. Choose DEWESoft data collection and analysis system software as research means of cutting force. Through technical analysis and cutting force measurement technology development direction was predicted.

The Effects of Curvature Radius on Cutting Force and Stability during End Milling

2011 ◽  
Vol 314-316 ◽  
pp. 1721-1726
Author(s):  
Wan Zhu Liu ◽  
Qiang Liu ◽  
Ge Gao ◽  
Xue Yan
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Milling Process ◽  
Radius Ratio ◽  
Curvature Radius ◽  
Stable Range ◽  
Large Radius ◽  
Optimal Parameters ◽  
Cutting Point ◽  
End Milling Process

The influence of radius ratio of cutting point and cutter on cutting force and stability during end milling process is presented in this paper. To derive motion equations, a 2 DOF mechanical model of end milling considering both regenerative and self-excited effects was established. Different ratio values during three milling conditions were analyzed. Cutting forces as well as stability under different radius ratios by changing curvature radius and cutter radius were elaborated respectively. The results show that when other parameters are set fixed, cutter with relative large radius has smaller cutting force and larger stable range. Cutters with same radius will overlap on cutting force when radius ratio is large enough even under different milling conditions. The proposed analysis on cutting force and stability can be used to determine the optimal parameters, such as cutter radius and spindle speed etc. to improve the accuracy and productivity.

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