High frequency bandwidth cutting force measurement in milling using capacitance displacement sensors

Albrecht, Andreas; Park, Simon S.; Altintaş, Yusuf; Pritschow, Günter

doi:10.1016/j.ijmachtools.2004.11.028

Cited by 175 publications

(85 citation statements)

References 7 publications

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“…[9] and [10]), the achieved improvements are twofold. Firstly, the conceived observer allows estimating the tool tip vibrations that is a useful information strictly connected to the surfaces quality of the processed workpiece.…”

Section: Cutting Tests -Steel Millingmentioning

confidence: 99%

“…5. For this reason, in the current work, an observer that exploits data coming not only from a single sensor (as done in [9]) has been developed. The introduced enhancement allows extending the observer compensating properties and makes it suitable for different milling scenarios.…”

Section: Experimental Setup and System Model Identificationmentioning

confidence: 99%

“…In some cases, even the change of the tool can significantly modify the machine dynamics especially in the high frequency range hence, a new experimental modal analysis and the above described procedure need to be performed again. Before developing the Kalman-based observer, the observability of the model was investigated by checking the observability matrix to be full rank according to the research work reported in [9].…”

Section: {̇(mentioning

confidence: 99%

“…(24)) is determined by minimization of the error covariance matrix = [̃ ̃]. The minimum error covariance matrix can be obtained by solving the Riccati equation as follows [9],…”

Section: Observer Tuningmentioning

confidence: 99%

“…For instance, Altintas et al [10] used piezo-electric load sensors mounted in the spindle housing, the measurements were processed by a Kalman filter in order to compensate the effects of structural flexibility on the force measurement. Albrecht et al [9] developed an indirect method for measuring the cutting forces: it was based on the spindle shaft displacements measurements performed with capacitance sensors and on Kalman filtering processing. They also designed a setup based on three displacement sensors (placed at 120 degrees) suitable for two-dimensional forces (milling) indirect estimation and for the automatic temperature compensation.…”

Section: Introductionmentioning

confidence: 99%

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Model-based broadband estimation of cutting forces and tool vibration in milling through in-process indirect multiple-sensors measurements

Albertelli

Goletti

Torta

et al. 2015

Int J Adv Manuf Technol

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In machining processes, cutting forces measurement is essential to allow cutting process and tool conditions monitoring. Moreover, in order to have information about the quality of the milled part, the amplitude of the tool tip vibration would be very useful. Since both the measurements are extremely complicated especially in an industrial scenario, in this study, an in-process model based estimator of cutting forces and tool tip vibration was designed and properly tested. The developed estimator relies on both a machine dynamic model and on indirect measurements coming from multiple sensors placed in the machine. The machine dynamic model was obtained through an experimental modal analysis session. The estimator was developed according to the Kalman Filter approach. The fusion of multiple sensors data allowed the compensation of machine tool dynamics over an extended frequency range. The accuracy of the observer estimations was checked performing two different experimental sessions in which both the force applied to tool and the tool tip vibration amplitude were measured. In the first session, the tool was excited with different sensorized hammers in order to appreciate the broad-bandwidth of the performed estimations. In the second one, real cutting tests (steel milling) were done and the cutting forces were measured through a dynamometer, tool tip vibrations were measured as well. The experimental results showed that the indirect estimation of cutting forces and tool tip vibrations exhibit a good agreement with respect to the corresponding measured quantities in low and high frequency ranges. The contribution of this research is twofold. Firstly, the conceived observer allows estimating the tool tip vibrations that is a useful information strictly connected to the surfaces quality of the processed workpiece. Secondly, thanks to a multi-sensors approach, the frequency bandwidth is extended especially in the low frequency range.

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Section: Cutting Tests -Steel Millingmentioning

confidence: 99%

Section: Experimental Setup and System Model Identificationmentioning

confidence: 99%

Section: {̇(mentioning

confidence: 99%

“…(24)) is determined by minimization of the error covariance matrix = [̃ ̃]. The minimum error covariance matrix can be obtained by solving the Riccati equation as follows [9],…”

Section: Observer Tuningmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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