Indirect cutting force measurement in the micro end-milling process based on frequency analysis of sensor signals

Abstract

In this study, a useful indirect cutting force measurement method using an acceleration sensor and current hall sensors is proposed. A series of experiments was performed on a precise micro machining stage with a high-speed spindle. A three-axis acceleration sensor was installed on the spindle head, and current hall sensors were connected to the motor current inlet cables. From the results obtained, the correlations of the tool teeth rotation and current amplitude showed a linearity of 92.0% precision for hall sensor signals, and 98.0% precision for acceleration sensor signals. Even though the results using the acceleration sensor showed better linearity than those of the current hall sensors, the signals can be easily affected by chattering, spindle vibration, and other external disturbances. From this perspective, the current hall sensor can provide more robust results.

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining

“…Shin et al [14] proposed a method for predicting cutting force in end-milling process with an acceleration sensor and Hall-effect current sensors. Stein et al [42] proposed a dynamic lumped parameter model to characterize the current of a DC motor of a CNC machine tool, the electric current was used to calculate the cutting force and the forces associated with drive system components.…”

“…The indirect sensing approaches detect related parameters that change to some degree with cutting force such as spindle motor current, voltage, acceleration, acoustic emission, and vibration, etc. [13,14,15,16,17,18,19,20,21,22]. On the other hand, the direct sensing approaches are those that employ specific effects caused directly by cutting force.…”

Mathematical models of flank wear using vibration amplitude ratio in drilling

“…The authors have conducted experiments without any coolant and also suggested that special retro-fitting required for holding dynamometer on CNC turret lathe. Shin et al, [9] have suggested indirect cutting force measurement through use of acceleration sensor and current hall sensor frequency analysis for micro and milling process. Based on the results reported, they conclude that the predictions that are achieved by calculations had better linearity using an acceleration sensor compared to a current hall sensor.…”

Design and Analysis of a Sensor System for Cutting Force Measurement in Machining Processes

“…The most common indirect approaches to cutting force measurement or monitoring are based upon motor current and power measurement [ 4 , 5 ]. Shin et al [ 6 ] designed an indirect approach for measuring cutting force in end-milling process with a three-axis acceleration sensor and Hall-effect current sensors. An indirect approach for detecting cutting force for an Adaptive Control with Constraints (ACC) system for machining centers by using the currents of a.c. feed-drive servo drives was reported in [ 7 ].…”