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Primary testing of an instrumented tool holder for brush deburring of milled workpieces

Ramsauer Christoph, Oswald Ralf, Schörghofer Paul, Leder Norbert, Schmitz Tony, Bleicher Friedrich

Journal of Machine Engineering

2022

Vol. 22, No. 2

99--107

Brush deburring requires consistent contact pressure between brush and workpiece. Automating adjustments to control contact pressure has proven difficult, as the sensors available in machine tools are usually not suitable to observe the small amplitude signals caused by this low force process. Additionally, both the power consumption and the vibration signal caused by the process strongly depend on the workpiece surface features. This paper describes a test setup using an instrumented tool holder and presents the corresponding measurement results, aiming to quantify the axial feed of the brush. It also discusses the interpretation of different signal components and provides an outlook on the utilization of the data for tool wear estimation.

Using sensory tool holder data for optimizing production processes

Schörghofer Paul, Pauker Florian, Leder Norbert, Mangler Jürgen, Ramsauer Christoph, Bleicher Friedrich

Journal of Machine Engineering

2019

Vol. 19, No. 3

43--55

Today's highly automated manufacturing specifies the service time of a tool in a way that the tooling costs are balanced against the potential costs of a tool failure. However, the potential cost induced by a tool malfunctioning are rather high. Therefore, the current state-of-the art tackles this issue by replacing the tools prematurely at fixed intervals. To tap into the potential of under-utilized tool runtime this work purposes the use of sensory-tool holders and an interfering feedback loop to the machine tool control system. Besides its real-time closed loop control, to avoid tool failure, it also provides data in the context of (a) the work order, (b) the produced part, (c) the NC-block and command line, on (d) specific machines. Based on this data an ex-post analysis to optimize tool-life and productivity scenarios becomes possible, e.g. custom NC-programs for certain work-orders, configurations and machines. Furthermore, downstreamed work steps can be changed e.g. only to measure produced workpieces if abnormal vibrations are reported by in-process-monitoring.