Cutting torque and tangential cutting force coefficient identification from spindle motor current

Aggarwal, Seema; Nešić, Nenad; Xirouchakis, Paul

doi:10.1007/s00170-012-4152-x

Cited by 45 publications

(21 citation statements)

References 19 publications

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“…That is, the surface profile error can be directly determined by the applied feed rate and axial cut depth during milling operation. By curve fitting on the realistic experiments undertaken beforehand, the current applied to spindle motor with respect to rotational spindle speed can be expressed as follows [14]:…”

Section: Milling Dynamicsmentioning

confidence: 99%

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Cutting torque feedback control for thin-wall conical workpieces

Tsai

Yeh

2015

Int J Adv Manuf Technol

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An innovative approach of online cutting torque estimation and real-time feedback control for thin-wall tubular geometry workpieces is proposed and verified by experiments. This research is focused on how to formulate the appropriate applied cutting torque estimated by the feedback of current to spindle motor during milling process so that the milling cycle can be greatly reduced. On the other hand, a few suitable cutting conditions to prevent potential break/ crack of thin-wall workpieces that enhance productivity but almost retain the same cutting quality are addressed as well. To achieve these goals, the milling dynamics of the thin-wall tubular geometry workpieces, including milling vibration and static deflection, is constructed at first. Based on the dynamic model, a fuzzy adaptive torque tuning (FATT) control strategy is synthesized to adaptively maximize the vertical feed rate under the constraint of preset upper limit of surface profile error on workpieces. Finally, the milling experiments and surface profile error measurements for the thin-wall tubular geometry workpiece have been undertaken to examine the effectiveness of proposed FATT strategy. Compared with constant cutting torque policy, it is observed that the vertical feed rate can be increased by 230 % under FATT. It implies that the required milling cycle is greatly shortened more than 70 % while the corresponding cutting accuracy upon finish of workpiece can be almost retained.

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Section: Milling Dynamicsmentioning

confidence: 99%

“…The estimated cutting torque, T c , with respect to spindle speed, ω m , and the actual spindle motor current at cutting mode, I, can be described as follows [14]:…”

Section: Milling Dynamicsmentioning

confidence: 99%

Cutting torque feedback control for thin-wall conical workpieces

Tsai

Yeh

2015

Int J Adv Manuf Technol

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“…It is noteworthy that Kim GD and Chu CN, 26 X Li et al, 27 and S Aggarwal et al 28 proposed indirect cutting force measurement by monitoring motor current. This method has good accuracy and can also be used for indirect energy measurement.…”

Section: Introductionmentioning

confidence: 99%

“…With the development of technology for digital servo controllers, intelligent components integrated with internal and external sensors are widely adopted in CNC machine tools. 28,29 The motor current signal and speed controlled by the digital servo can be read out and written by the CNC and PC real time. This is a novel indirect method to measuring and calculating information such as cutting power and input power.…”

Section: Introductionmentioning

confidence: 99%

Measuring and calculating the computer numerical control lathe’s cutting power and total electric power consumption based on servo parameters

Liu

Zhang

Liu

et al. 2017

Advances in Mechanical Engineering

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Improving the energy efficiency of machine tools is the goal of sustainable development of the mechanical manufacturing industry. The key is to measure or calculate energy efficiency conveniently and accurately. This article proposes a method of calculating power by reading the computer numerical control system's servo parameters from its currentloop and speed-loop, establishing the relationships between cutting power, total power, and servo parameters, and using these relationships for power prediction. Experiments were done on a computer numerical control lathe. The result shows that this method has high precision, does not need additional sensors, and is independent of cutting process parameters, workpiece material, heat treatment state, and tools. This method may be used for developing a cutting power management module integrated in the computer numerical control system with real-time monitoring power consumption because the computer numerical control system can read servo parameters real time.

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“…Many other machining physical variables, such as cutting force and tool wear, are related to the feed-motor current. Aggarwal et al [11] identified the cutting torque and tangential cutting force coefficient from the spindle motor current, Jeong and Cho [12] estimated the cutting force from the rotating and stationary feed-motor current, and Rizal et al [3] detected the tool breakage in CNC high-speed milling based on the feed-motor current. Kim and Jeon [13] show that feedmotor is better for the control of the CNC milling process than cutting forces.…”

Section: Introductionmentioning

confidence: 99%

Modeling of the Feed-Motor Transient Current in End Milling by Using Varying-Coefficient Model

Xiao

Wen

et al. 2015

Mathematical Problems in Engineering

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In order to ensure the stability of the machining process, it is vital to control the machining condition during the milling process. While the feed-motor current is related to many physical variables, such as the cutting force and tool wear, we can indicate it as the key variables to monitoring the conditions of the milling process. A predictive model of the feed-motor current amplitude is established in this paper. The change regulation of the transient current amplitude during the milling process is investigated, and the effect of the spindle speed on the transient current amplitude is studied as well. Since the transient current amplitude is time-varying, the predictive model is a typical panel data type. In this case, the varying-coefficient model (VCM), a potential soft computing method, is applied to solve this predictive model. Then several experiments are conducted to evaluate the performance of VCM method. Results show that the predicted values match the experimental value well, and the correctness of the predictive model for transient current amplitude is also validated.

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Cutting torque and tangential cutting force coefficient identification from spindle motor current

Cited by 45 publications

References 19 publications

Cutting torque feedback control for thin-wall conical workpieces

Cutting torque feedback control for thin-wall conical workpieces

Measuring and calculating the computer numerical control lathe’s cutting power and total electric power consumption based on servo parameters

Modeling of the Feed-Motor Transient Current in End Milling by Using Varying-Coefficient Model

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