Abstract
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.
Highlights
Cutting force, which is originated by the shearing of the material, friction between the chip and the cutter and so on, can convey key information on the conditions of machining processes.The cutting forces can reflect the machinability of the material [1,2] or used to identify machining malfunctions, such as machining vibrations [3,4] or tool wear [5]
Luo et al [22] integrated the polyvinylidene fluoride (PVDF) thin-film sensors into the index-able tools to measure cutting forces acting on separate insert, the signals are transmitted by a wireless transmitter, and the signals are used to identify the insert working condition in the milling process
If the force component is applied only on the normal face of the sensor, the strain mainly exists in the normal direction, the shear strain caused by torsion or slide is neglected here since mainly exists in the normal direction, the shear strain caused by torsion or slide is neglected here the PVDF sensor is insensitive to the in-plane shear strain
Summary
Cutting force, which is originated by the shearing of the material, friction between the chip and the cutter and so on, can convey key information on the conditions of machining processes. Luo et al [22] integrated the PVDF thin-film sensors into the index-able tools to measure cutting forces acting on separate insert, the signals are transmitted by a wireless transmitter, and the signals are used to identify the insert working condition in the milling process. Liu et al [23] designed an integrated rotating dynamometer based on fiber Bragg grating (FBG) to measure four-component cutting force These methods mainly integrate sensing components into the cutting tool, this is easy to be disturbed by the machining process since rigidity of the spindle is relatively low. Machining process monitoring is an emerging requirement in the Industry 4.0 era, where the concept of integrating sensors into machine tools is a promising way that will not have a large influence on existing production lines To this end, an instrumented working table with embedded.
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