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TECHNICAL PAPERS

Identification of Spindle Integrated Force Sensor’s Transfer Function for Modular End Mills

[+] Author and Article Information
Simon S. Park

Department of Mechanical and Manufacturing Engineering, University of Calgary, Calgary, AB T2N 1N4, Canadasimon.park@ucalgary.ca

J. Manuf. Sci. Eng 128(1), 146-153 (Aug 11, 2005) (8 pages) doi:10.1115/1.2137749 History: Received June 16, 2003; Revised August 11, 2005

A spindle integrated cutting force system where piezoelectric force sensors are embedded in the spindle housing is studied. The transfer function between the force experienced at the end mill and measured at the spindle integrated force sensor varies depending on the tool length sticking out. In the paper, a method is proposed to predict the transfer function of the overall system by coupling the receptances of the analytically modeled end mill and experimentally measured spindle structures. The experimentally proven method allows for the automated calibration of the spindle integrated force system whenever a tool change occurs to accurately measure high-frequency bandwidth cutting forces.

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Copyright © 2006 by American Society of Mechanical Engineers
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Figures

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Figure 3

Cylindrical blanks and four fluted end mill used in identifying the spindle-tool holder joint dynamics

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Figure 4

Frequency responses of spindle/tool holder and long blank

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Figure 7

Comparison between the experimentally measured FRF to the analytically coupled spindle and end mill force/force FRF (i.e., Φ31,ff)

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Figure 8

Pole-zero map of (a) the fitted transfer function and (b) the Kalman filter transfer function

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Figure 9

FRFs of the model, Kalman filter, and compensated spindle integrated force sensing system (Model FRF: FRF identified using the RC; KF FRF: FRF of the Kalman filter; Cascaded FRF: Cross product of Model FRF and KF FRF)

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Figure 10

Four fluted half-immersion down milling force measurements at 7000rpm (Top figure: time domain; Bottom figure: frequency domain normalized with the spindle frequency). The spindle and tooth passing frequencies at 7000rpm correspond to 116.67 and 466.67Hz, respectively.

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Figure 1

(a) Spindle/tool holder and tool substructures, (b) arrangement of the sensors from the top view

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Figure 2

Coupling of force/force cross transfer function with an arbitrary end mill

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Figure 5

Identified rotational FRFs at the joint

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Figure 6

Predicted and measured FRFs (H11,ff) of the long blank attached to the spindle when the rotational dynamics are considered

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