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Flexure-based dynamometer for vector-valued milling force measurement

Ramsauer Christoph, Leitner David, Habersohn Christoph, Schmitz Tony, Yamazaki Kazuo, Bleicher Friedrich

Journal of Machine Engineering

2023

Vol. 23, No. 1

47--56

Variation in cutting forces with cutting parameter selection, tool geometry, and wear status plays an important role for milling process evaluation and modeling. While piezoelectric force measurement is commercially available, it is often considered a precise but expensive method. This paper presents a novel solution for vector-valued cutting force measurement. The table-mounted, flexure-based kinematics provide three degrees of freedom that are used to measure the in-process milling force vector components in the working plane by low-cost optical sensors. Based on analytical models and FEM analysis, an appropriate design was derived. The assembly and testing of the developed dynamometer are presented. A test setup based on a machining center was used for the system evaluation and the data are compared to the forces measured by a commercially available, piezoelectric cutting force dynamometer.

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.