Abstract
Thin-walled workpieces, such as aero-engine blisks and casings, are usually made of hard-to-cut materials. The wall thickness is very small and it is easy to deflect during milling process under dynamic cutting forces, leading to inaccurate workpiece dimensions and poor surface integrity. To understand the workpiece deflection behavior in a machining process, a new real-time nonintrusive method for deflection monitoring is presented, and a detailed analysis of workpiece deflection for different machining stages of the whole machining process is discussed. The thin-film polyvinylidene fluoride (PVDF) sensor is attached to the non-machining surface of the workpiece to copy the deflection excited by the dynamic cutting force. The relationship between the input deflection and the output voltage of the monitoring system is calibrated by testing. Monitored workpiece deflection results show that the workpiece experiences obvious vibration during the cutter entering the workpiece stage, and vibration during the machining process can be easily tracked by monitoring the deflection of the workpiece. During the cutter exiting the workpiece stage, the workpiece experiences forced vibration firstly, and free vibration exists until the amplitude reduces to zero after the cutter exits the workpiece. Machining results confirmed the suitability of the deflection monitoring system for machining thin-walled workpieces with the application of PVDF sensors.
Highlights
Thin-walled workpieces, such as aero-engine blisks and casings, are usually made of hard-to-cut materials
The machining accuracy and surface integrity is important for thin-walled workpieces to ensure the service life and working performance
The input of the monitoring system is the deflection of the polyvinylidene fluoride (PVDF) sensor, and the output is the voltage; we have to establish the relationship between the input and the output
Summary
Thin-walled workpieces, such as aero-engine blisks and casings, are usually made of hard-to-cut materials (titanium alloy or Ni-based alloy). PVDF-based sensors have been frequently used in industry for energy harvesting [5], vibration monitoring and control [6], pressure monitoring [7,8], dynamic force measurement [9], and machining process monitoring [10,11]. Ma et al [11] mounted the PVDF sensor on the milling cutter to measure the cutting forces in a machining process. The monitored real-time deflection data can be used machining process improvement of thin-walled workpieces.
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