Low Cost, High Bandwidth, and Non-Intrusive Machining Force Measurement System

该奖项由2009年美国复苏和再投资法案(公法111-5)资助。该奖项的研究目标是在足够的带宽下非侵入性地测量铣削过程中的切削力，以实现闭环控制。研究方法包括扩展时域有限差分方法，以精确模拟直接安装在刀具上的小电感-电容环路结构的应变引起的谐振响应变化。该方法将被用于识别最敏感的应变结构，然后通过实验验证这些结构可以准确地测量切削力。完成后，将在切割过程中动态测量侧向力和扭转力，以监控切割效率和质量，并检测刀具退化和/或故障。这项工作的更广泛影响是扩展了时域有限差分方法，使其适用于所有高频电子设备中存在的小结构，并将通过提供用于加工的闭环控制的传感器系统来改变加工过程，而目前尚不具备这些功能。拥有闭环控制将使智能机床体系结构的发展成为可能，这将对铣削过程的生产率产生重大影响，同时提高成品零件的质量。最终目标是使该系统成为高端加工系统的标准部件，从而改变铣削加工中的金属去除过程。

This award is funded under the American Recovery and Reinvestment Act of 2009 (Public Law 111-5).The research objective of this award is to non-intrusively measure cutting forces during milling at sufficient bandwidth to enable closed-loop control. The research approach consists of extending finite difference time domain methods to accurately model the strain-induced changes in resonant response of small inductor-capacitor loop structures to be mounted directly on the tool. This method will be used to identify the most strain sensitive structures followed by experimental verification that these structures can accurately measure cutting forces. When this is accomplished, the lateral and torsional forces will be dynamically measured during cutting to monitor cutting efficiency and quality as well as detect tool degradation and/or failure. The broader impacts of this work are extending finite difference time domain methods so that they are applicable to the small structures present in all high frequency electronics and that it will transform the process of milling by providing a sensor system for closed-loop control of machining where none having these capabilities currently exists. Having closed-loop control will enable the development of smart machine tool architectures which will have a dramatic impact on the productivity of the milling process while simultaneously improving the quality of the finished parts. The ultimate goal is to make this system a standard component in high end machining systems, thereby transforming the metal removal process in milling.