Transactions of the Korean Society of Machine Tool Engineers (한국공작기계학회논문집)

The Korean Society of Manufacturing Technology Engineers (한국생산제조학회)
권호 표지

A Cylindrical Spindle Displacement Sensor and its Application on High Speed Milling Machine

원통형 주축 변위 센서를 이용한 고속 밀링 가공 상태 감시

  • Published : 2007.10.15
Download PDF
⟨ Previous Next ⟩

Abstract

A new cutting force estimating approach and machining state monitoring examples are presented which uses a cylindrical displacement sensor built into the spindle. To identify the tool-spindle system dynamics with frequency up to 2 kHz, a home-built electro-magnetic exciter is used. The result is used to build an algorithm to extract the dynamic cutting force signal from the spindle error motion; because the built-in spindle sensor signal contains both spindle-tool dynamics and tool-workpiece interactions. This sensor is very sensitive and can measure broadband signal without affecting the system dynamics. The main characteristic is that it is designed so that the measurement is irrelevant to the geometric errors by covering the entire circumferential area between the target and sensor. It is also very simple to be installed. Usually the spindle front cover part is copied and replaced with a new one with this sensor added. It gives valuable information about the operating condition of the spindle at any time. It can be used to monitor cutting force and chatter vibration, to predict roughness and to compensate the form error by overriding spindle speed or feed rate. This approach is particularly useful in monitoring a high speed machining process.

Keywords

References

  1. Chung, Y. L. and Spiewak, S. A., 1994, 'A model of high performance dynamometer,' ASME Trans. Journal of Engineering for Industry, Vol. 116, pp. 279-288 https://doi.org/10.1115/1.2901943
  2. Tounsi, N. and Otho, A., 2000, 'Dynamic cutting force measuring,' Int. J. of Machine Tools & Manufacture, Vol. 40, pp. 1157-1170 https://doi.org/10.1016/S0890-6955(99)00117-0
  3. Spiewak, S. A., 1995, 'Acceleration based indirect force measurement in metal cutting processes,' Int. J. of Machine Tools & Manufacture, Vol. 35, No. 1, pp. 1-17 https://doi.org/10.1016/0890-6955(95)80005-0
  4. Kim, T. Y. and Kim, J. W., 1996, 'Adaptive cutting for ce control for a machining center by using indirect cutting force measurements,' Int. J. of Machine Tools & Manufacture, Vol. 36, No. 8, pp. 925-937 https://doi.org/10.1016/0890-6955(96)00097-1
  5. Jeong, Y. H. and Cho, D. W., 2002, 'Estimating cutting force from rotating and stationary feed motor currents on a milling machine,' Int. J. of Machine Tools & Manufacture, Vol. 42, pp. 1559-1566 https://doi.org/10.1016/S0890-6955(02)00082-2
  6. Auchet, S., Chevrier, P., Lacour, M. and Lipinski, P., 2004, 'A new method of cutting force measurement based on command voltages of active electro-magnetic bearings,' Int. J. of Machine Tools & Manufacture, Vol. 44, pp. 1441-1449 https://doi.org/10.1016/j.ijmachtools.2004.05.009
  7. Kim, I. H., Jang, D. Y., Kim, W. J. and Han, D. C., 2001, 'In-process sensing of tool wear and process states using a cylindrical displacement sensor in hard turning,' Proc. of the Institution of Mechanical Engineers, Part B: J. of Engineering Manufacture, Vol. 215, No. 12, pp. 1673-1682 https://doi.org/10.1243/0954405011519501
  8. Kim, I. H. and Jang, D. Y., 2003, 'Cutting vibration monitoring using a spindle displacement sensor in turning,' Proc. of DETC'03, ASME, Chicago, Illinois, USA
  9. Albrecht, A., Park, S. S., Altintas, Y. and Pritschow, G., 2005, 'High frequency bandwidth cutting force measurement in milling using capacitance displacement sensors,' Int. J. of Machine Tools & Manufacture, Vol. 45, pp. 993-1008 https://doi.org/10.1016/j.ijmachtools.2004.11.028
  10. Smith, P. T., Vallance, R. R. and Marsh, E. R., 2005, 'Correcting capacitive displacement measurements in metrology applicatoins with cylindrical artifacts,' Precision Engineering, Vol. 29, pp. 324-335 https://doi.org/10.1016/j.precisioneng.2004.11.010
  11. Jun, M. B., Ozdoganlar, O. B., DeVor, R. E., Kappor, S. G., Kirchheim, A. and Schaffner, G., 2002, 'Evaluation of a spindle-based force sensor for monitoring and fault diagnosis of machining operations,' Int. J. of Machine Tools & Manufacture, Vol. 42, pp. 741-751 https://doi.org/10.1016/S0890-6955(01)00156-0
  12. Li, H. and Shin, Y. C., 2004, 'Analysis of bearing configuration effects on high speed spindles using an integrated dynamic thermo-mechanical spindle model,' Int. J. of Machine Tools & Manufacture, Vol. 44, pp. 347-364 https://doi.org/10.1016/j.ijmachtools.2003.10.011
  13. Chang, H. K., Kim, J. H., Kim, I. H., Jang, D. Y. and Han, D. C., 2007, 'In-process surface roughness prediction using displacement signals from spindle motion,' Int. J. of Machine Tools & Manufacture, Vol. 47, pp. 1021-1026 https://doi.org/10.1016/j.ijmachtools.2006.07.004
  14. Mann, B. P., Young, K. A., Schmitz, T. L. and Dilley, D. N., 2005, 'Simultaneous stability and surface location error predictions in milling,' ASME Tran. Journal of Manufacturing Science and Engineering, Vol. 127, pp. 446-453 https://doi.org/10.1115/1.1948394