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Research Papers

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

[+] Author and Article Information
Lei Ma, Shreyes N. Melkote, John B. Morehouse, James B. Castle, James W. Fonda, Melissa A. Johnson

George W. Woodruff School of Mechanical Engineering,  Georgia Institute of Technology, Atlanta, GA 30332Manufacturing Research Center,  Georgia Institute of Technology, Atlanta, GA 30332The Boeing Company,Boeing Research & Technology, St. Louis, MO 63166The Boeing Company,Boeing Research & Technology, Seattle, WA 98124

μɛ stands for microstrain

The sign convention indicated in Fig. 3 is used.

J. Dyn. Sys., Meas., Control 134(5), 051014 (Jul 27, 2012) (9 pages) doi:10.1115/1.4006366 History: Received April 28, 2011; Revised February 16, 2012; Accepted February 22, 2012; Published July 26, 2012; Online July 27, 2012

A sensor module that integrates a thin film polyvinylidene fluoride (PVDF) piezoelectric strain sensor and an in situ data logging platform has been designed and implemented for monitoring of the feed and transverse forces in the peripheral end milling process. The module, which is mounted on the tool shank, measures the dynamic strain(s) produced in the tool and logs the data into an on-board card for later retrieval. The close proximity between the signal source and the PVDF sensor(s) minimizes the attenuation and distortion of the signal along the transmission path and provides high-fidelity signals. It also facilitates the employment of a first principles model based on the Euler–Bernoulli beam theory and constitutive equations of the piezoelectric sensor material to relate the in situ measured PVDF sensor signals to the feed and transverse forces acting on the tool. The PVDF sensor signals are found to compare well with the force signals measured by a platform-type piezoelectric force dynamometer in peripheral end milling experiments.

FIGURES IN THIS ARTICLE
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Copyright © 2012 by American Society of Mechanical Engineers
Topics: Force , Sensors , Cutting , Signals , Milling
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References

Figures

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Figure 1

Force measurement system setup for peripheral end milling

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Figure 2

Signal flow of the force measurement system

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Figure 3

Schematic of PVDF sensor deployment in peripheral end milling process

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Figure 4

Frequency response function of the cutting tool/tool holder/spindle/machine tool system used in the study (see Fig. 1)

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Figure 5

Schematic of a PVDF sensor element

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Figure 6

Angular span of the PVDF sensor on the cutting tool shank

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Figure 7

Bode plot of the transfer function of the signal conditioning circuitry

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Figure 8

Backward comparison between the reference signal and the in situ measured PVDF sensor signal (cutting test no. 1)

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Figure 9

Backward comparison between the reference signal and the in situ measured PVDF sensor signal (cutting test no. 10)

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Figure 10

Backward comparison between the reference signal and the in situ measured PVDF sensor signal (cutting test no. 15)

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Figure 11

Backward comparison between the reference signal and the in situ measured PVDF sensor signal (cutting test no. 17)

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Figure 12

Discrete time compensation of the attenuation and distortion introduced by the signal conditioning circuitry

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Figure 13

Forward comparison between the forces calculated from the PVDF sensor signal and the dynamometer measurements (cutting test no. 1: tool entry stage of cutting)

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Figure 14

Forward comparison between the forces calculated from the PVDF sensor signal and the dynamometer measurements (cutting test no. 1: stable cutting stage)

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