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Keywords = wireless sensory tool holder

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25 pages, 12596 KB  
Article
Multi-Sensory Tool Holder for Process Force Monitoring and Chatter Detection in Milling
by Alexander Schuster, Andreas Otto, Hendrik Rentzsch and Steffen Ihlenfeldt
Sensors 2024, 24(17), 5542; https://doi.org/10.3390/s24175542 - 27 Aug 2024
Cited by 14 | Viewed by 3789
Abstract
Sensor-based monitoring of process and tool condition in milling is a key technology for improving productivity and workpiece quality, as well as enabling automation of machine tools. However, industrial implementation of such monitoring systems remains a difficult task, since they require high sensitivity [...] Read more.
Sensor-based monitoring of process and tool condition in milling is a key technology for improving productivity and workpiece quality, as well as enabling automation of machine tools. However, industrial implementation of such monitoring systems remains a difficult task, since they require high sensitivity and minimal impact on CNC machines and cutting conditions. This paper presents a novel multi-sensory tool holder for measurement of process forces and vibrations in direct proximity to the cutting tool. In particular, the sensor system has an integrated temperature sensor, a triaxial accelerometer and strain gauges for measurement of axial force and bending moment. It is equipped with a self-sufficient electric generator and wireless data transmission, allowing for a tool holder design without interfering contours. Milling and drilling experiments with varying cutting parameters are conducted. The measurement data are analyzed, pre-processed and verified with reference signals. Furthermore, the suitability of all integrated sensors for detection of dynamic instabilities (chatter) is investigated, showing that bending moment and tangential acceleration signals are the most sensitive regarding this monitoring task. Full article
(This article belongs to the Special Issue Emerging Sensing Technologies for Machine Health State Awareness)
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14 pages, 2221 KB  
Article
Machined Surface Quality Monitoring Using a Wireless Sensory Tool Holder in the Machining Process
by Zhiyuan Lu, Meiqing Wang and Wei Dai
Sensors 2019, 19(8), 1847; https://doi.org/10.3390/s19081847 - 18 Apr 2019
Cited by 27 | Viewed by 4791
Abstract
The quality of a machined surface plays a critical role in assembly performance, especially for precise matching parts, and therefore it is necessary to develop a surface quality monitoring system in the machining process. In this paper, an indirect surface quality monitoring approach [...] Read more.
The quality of a machined surface plays a critical role in assembly performance, especially for precise matching parts, and therefore it is necessary to develop a surface quality monitoring system in the machining process. In this paper, an indirect surface quality monitoring approach is proposed with a wireless sensory tool holder. First, experimentation is conducted to collect the machining process signals from the tool holder. Then, the time domain, frequency domain and time–frequency domain features are extracted, and the deep forest algorithm is adopted to identify the surface quality, which is evaluated through the surface average parameter. Finally, the results of the experiment and the comparisons with other approaches demonstrate the effectiveness of the proposed method, which could be applied to ensure the surface quality, improve the machining efficiency and reduce the rejection rate of the machining process. Full article
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