Next Article in Journal
A Novel Slope Method for Measurement of Fluid Density with a Micro-cantilever under Flexural and Torsional Vibrations
Previous Article in Journal
Improved Bearings-Only Multi-Target Tracking with GM-PHD Filtering
Article Menu

Export Article

Open AccessArticle
Sensors 2016, 16(9), 1470; doi:10.3390/s16091470

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

Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of Education, Northwestern Polytechnical University, Xi’an 710072, China
*
Author to whom correspondence should be addressed.
Academic Editor: Vittorio M. N. Passaro
Received: 30 June 2016 / Revised: 28 August 2016 / Accepted: 6 September 2016 / Published: 10 September 2016
(This article belongs to the Section Physical Sensors)
View Full-Text   |   Download PDF [8366 KB, uploaded 10 September 2016]   |  

Abstract

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. View Full-Text
Keywords: real-time monitoring; workpiece deflection; vibration; PVDF sensor; thin-walled workpiece; thin-film sensor real-time monitoring; workpiece deflection; vibration; PVDF sensor; thin-walled workpiece; thin-film sensor
Figures

Figure 1

This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

Scifeed alert for new publications

Never miss any articles matching your research from any publisher
  • Get alerts for new papers matching your research
  • Find out the new papers from selected authors
  • Updated daily for 49'000+ journals and 6000+ publishers
  • Define your Scifeed now

SciFeed Share & Cite This Article

MDPI and ACS Style

Luo, M.; Liu, D.; Luo, H. 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. Sensors 2016, 16, 1470.

Show more citation formats Show less citations formats

Note that from the first issue of 2016, MDPI journals use article numbers instead of page numbers. See further details here.

Related Articles

Article Metrics

Article Access Statistics

1

Comments

[Return to top]
Sensors EISSN 1424-8220 Published by MDPI AG, Basel, Switzerland RSS E-Mail Table of Contents Alert
Back to Top