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Article

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
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Academic Editor: Vittorio M. N. Passaro
Sensors 2016, 16(9), 1470; https://doi.org/10.3390/s16091470
Received: 30 June 2016 / Revised: 28 August 2016 / Accepted: 6 September 2016 / Published: 10 September 2016
(This article belongs to the Section Physical Sensors)
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
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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. https://doi.org/10.3390/s16091470

AMA 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(9):1470. https://doi.org/10.3390/s16091470

Chicago/Turabian Style

Luo, Ming, Dongsheng Liu, and Huan Luo. 2016. "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 16, no. 9: 1470. https://doi.org/10.3390/s16091470

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