Thin-Film PVDF Sensor-Based Monitoring of Cutting Forces in Peripheral End Milling

Ma, Lei; Melkote, Shreyes N.; Morehouse, John B.; Castle, James; Fonda, James W.; Johnson, Melissa

doi:10.1115/1.4006366

Cited by 40 publications

(21 citation statements)

References 30 publications

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“…Fan et al [30] developed a method for monitoring the pressure distribution through a set of capacitive sensors embedded within the roll. Ma et al [31] proposed a sensor module that integrates a thin film polyvinylidene fluoride piezoelectric strain sensor and an in-situ data logging platform for monitoring of the feed and transverse forces in the peripheral end milling process. Wang et al [32] developed a smart cutting tool realizing the feed rate adjustment and then modifying the orthogonal cutting force.…”

Section: Integration Of Machining and Monitoringmentioning

confidence: 99%

An integrated feature-based dynamic control system for on-line machining, inspection and monitoring

Liu

Gao

et al. 2015

ICA

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Manufacturing companies dealing with high value, high accuracy and complex parts are facing increasing demand for higher quality and efficiency at lower costs and reduced lead times from their global customers. In real-life production such as the Numerical Control (NC) machining processes, there are continuous changes in machine tool performance, cutting tool conditions, workpiece deformation, cutting parameters, in addition to the changes in the geometry and properties of the parts being machined. Some changes are caused by 'predictable' factors such as cutting forces and machine tool deterioration over time, whilst others are caused by 'unpredictable' factors such as sudden breakdowns, uneven material property, vibration and machining chatter, or even human errors. These dynamic factors impose significant difficulties to ensuring machining accuracy effectively especially the controlling of unrecoverable over-cut errors normally causing part failures. This project aims to establish a set of integrated information models to address the dynamics of machining conditions based on the Dynamic Feature concept proposed by the authors, which are used as the basis for integrating machining, monitoring, and on-line inspection operations for optimized machining process control of high value complex parts. A prototype framework based on an open platform has been developed to enable the application of the proposed method. Industrial examples used to validate the prototype will be presented in this paper.

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Section: Integration Of Machining and Monitoringmentioning

confidence: 99%

An integrated feature-based dynamic control system for on-line machining, inspection and monitoring

Liu

Gao

et al. 2015

ICA

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“…Stress/strain measurement methods for tool condition monitoring are established in literature using a variety of techniques. They include use of thin film sensors [60], photoelastic method [61], use of strain gauge [62], and use of optical fibre sensors [63].…”

Section: Actuator Current Measurementmentioning

confidence: 99%

“…In [60] authors have demonstrated a technique to capture the strain on milling tool using thin film polyvinylidene fluoride (PVDF) sensor and has proved its accuracy using back calculation of induced forces and matching them with the obtained ones using dynamometer. A strain gauge based milling dynamometer was proposed in [62], wherein strain gauges bonded on octagon rings were used to finally procure the cutting force.…”

Section: Actuator Current Measurementmentioning

confidence: 99%

Applicability of Tool Condition Monitoring Methods Used for Conventional Milling in Micromilling: A Comparative Review

Mandal

2014

Journal of Industrial Engineering

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Micromilling is a contact based material removal process in which a rotating tool with nose radius in microns is fed over a stationary workpiece. In the process small amount of material gets chipped off from the workpiece. Due to continuous contact between tool and workpiece significant damage occurs to the cutting tools. Mitigating tool damage to make micromilling systems more reliable for batch production is the current research trend. In macroscale or conventional milling process a number of methods have been proposed for tool condition monitoring. Few of them have been applied for micromilling. This paper reviews different methods proposed and used in last two decades for monitoring the condition of micromilling tools. Applicability of tool condition monitoring methods used in conventional milling has been compared with the similar ones proposed for micromilling. Further, the challenges and opportunities on the applicability issues have been discussed.

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“…Polyvinylidene fluoride (PVDF) is a kind of organic polymer piezoelectric material and is the piezoelectric polymer material with the most potential [ 3 , 4 ]. PVDF-based sensors have been frequently used in industry for energy harvesting [ 5 ], vibration monitoring and control [ 6 ], pressure monitoring [ 7 , 8 ], dynamic force measurement [ 9 ], and machining process monitoring [ 10 , 11 ]. Some previous studies have been focused on the application of PVDF sensors for deformation or deflection monitoring, as well as dynamic sensing.…”

Section: Introductionmentioning

confidence: 99%

“…Zeng et al [ 15 ] developed a sensor that was a hybrid of carbon black and PVDF for use in in situ acquisition of dynamic elastic disturbances of low frequency vibrations. Ma et al [ 11 ] mounted the PVDF sensor on the milling cutter to measure the cutting forces in a machining process. The measured data can be further used for on-line chatter detection in milling processes [ 10 ].…”

Section: Introductionmentioning

confidence: 99%

Real-Time Deflection Monitoring for Milling of a Thin-Walled Workpiece by Using PVDF Thin-Film Sensors with a Cantilevered Beam as a Case Study

Luo

Liu

Luo

2016

Sensors

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Thin-walled workpieces, such as aero-engine blisks and casings, are usually made of hard-to-cut materials. The wall thickness is very small and it is easy to deflect during milling process under dynamic cutting forces, leading to inaccurate workpiece dimensions and poor surface integrity. To understand the workpiece deflection behavior in a machining process, a new real-time nonintrusive method for deflection monitoring is presented, and a detailed analysis of workpiece deflection for different machining stages of the whole machining process is discussed. The thin-film polyvinylidene fluoride (PVDF) sensor is attached to the non-machining surface of the workpiece to copy the deflection excited by the dynamic cutting force. The relationship between the input deflection and the output voltage of the monitoring system is calibrated by testing. Monitored workpiece deflection results show that the workpiece experiences obvious vibration during the cutter entering the workpiece stage, and vibration during the machining process can be easily tracked by monitoring the deflection of the workpiece. During the cutter exiting the workpiece stage, the workpiece experiences forced vibration firstly, and free vibration exists until the amplitude reduces to zero after the cutter exits the workpiece. Machining results confirmed the suitability of the deflection monitoring system for machining thin-walled workpieces with the application of PVDF sensors.

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Thin-Film PVDF Sensor-Based Monitoring of Cutting Forces in Peripheral End Milling

Cited by 40 publications

References 30 publications

An integrated feature-based dynamic control system for on-line machining, inspection and monitoring

An integrated feature-based dynamic control system for on-line machining, inspection and monitoring

Applicability of Tool Condition Monitoring Methods Used for Conventional Milling in Micromilling: A Comparative Review

Real-Time Deflection Monitoring for Milling of a Thin-Walled Workpiece by Using PVDF Thin-Film Sensors with a Cantilevered Beam as a Case Study

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