Rectification of Piezoelectric Dynamometer Force Signals During Low Frequency Vibration Assisted Drilling

Abstract

In vibration assisted drilling (VAD), a controlled harmonic motion is superimposed over the principal drilling feed motion in order to create an intermittent cutting state, which reduces cutting forces and temperatures, facilitates chip removal, and increases the possibility for dry machining. However, accurate force measurements during VAD operations has been a challenge especially in systems, where the force transducer is part of the vibrating mass mounted on the shaker head, due to the dynamic force errors. Conventional signal filtering and compensation techniques were found to be not applicable for attenuating undesirable VAD dynamic force components, which exist in the measured force signals at the same frequency of superimposed modulation. This research work presents a corrective dynamic model that rectifies the erroneous VAD tangential and axial force signals measured by a commercial piezoelectric dynamometer mounted on electro-magnetic shakers for the low frequency/high amplitude (LF/HA) regime. An experimental modal analysis in tangential and axial directions was conducted in order to define the transfer function of a multiple degrees of freedom VAD system mounted on a vibrating base (shaker). The rectified force is then obtained by plugging the relative motion between the dynamometer base and face measured during cutting into the system transfer function. The predicted rectified force components showed very high conformance with known impact and sinusoidal excitation forces used for validation. Moreover, the developed corrective model was capable of predicting some features in the VAD force signals that were not fully captured in the measured force signals during cutting.