Abstract
The intensity of the clamping force during milling operations is very important, because an excessive clamping force can distort the workpiece, while inadequate clamping causes slippage of the workpiece. Since the overall clamping force can be affected by the cutting forces throughout machining, it is necessary to monitor the change of clamping and the cutting forces during the process. This paper proposes a hybrid system in the form of a vise with built-in strain gauges and in-house-developed piezoelectric sensors for simultaneous measurement of clamping and cutting forces. Lead zirconate titanate (PZT) sensors are fabricated and embedded in a layered jaw to measure the dynamic forces of the machine tool. A cross-shaped groove within the jaw is designed to embed strain gauges, which predominantly measure the static clamping forces. Sensor fusion technology combining the signals of the strain gauges and PZT piezoelectric sensors is used to investigate the interactions between cutting forces and clamping forces. The results show average errors of 11%, 17%, and 6% for milling forces in X, Y, and Z directions, respectively; and 19% error for clamping forces, confirming the capability of the setup to monitor the forces in milling.
Highlights
Global competition has posed a major challenge to industry, especially the manufacturing sector.While production cost and time are paramount, there are other expectations regarding the accuracy and quality of the products
This paper proposes the use of strain gauges for the measurement of the static forces because the electrostatic charge of PZT piezoelectric sensors decreases over time
This paper presents a novel, cost-effective force sensor system for the simultaneous measurement of cutting and clamping forces in milling operations
Summary
Global competition has posed a major challenge to industry, especially the manufacturing sector.While production cost and time are paramount, there are other expectations regarding the accuracy and quality of the products. One of the preliminary steps for precision manufacturing is to ensure that the workpiece is held stationary during the machining process. Machining vises are the most common devices used to hold a workpiece securely during different machining operations, such as milling and drilling. The workpiece must be stable within the vise throughout the machining process, which means the vise should fully restrain the workpiece subjected to static clamping forces and dynamically varying machining forces. Either lift-off or macro-slippage occurs at the jaw–workpiece contacts during the machining process [2]. The clamping forces can distort the workpiece. The distortion will cause dimensional inaccuracy if the clamping force is unnecessarily high [3]. Measuring the intensity of the clamping force while machining is very important to prevent the workpiece’s slippage or deformation
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