Development and testing of a wireless smart toolholder with multi-sensor fusion
Received date: 18 Jul 2023
Accepted date: 08 Oct 2023
Copyright
The smart toolholder is the core component in the development of intelligent and precise manufacturing. It enables in situ monitoring of cutting data and machining accuracy evolution and has become a focal point in academic research and industrial applications. However, current table and rotational dynamometers for milling force, vibration, and temperature testing suffer from cumbersome installation and provide only a single acquisition signal, which limits their use in laboratory settings. In this study, we propose a wireless smart toolholder with multi-sensor fusion for simultaneous sensing of milling force, vibration, and temperature signals. We select force, vibration, and temperature sensors suitable for smart toolholder fusion to adapt to the cutting environment. Thereafter, structural design, circular runout, dynamic balancing, static stiffness, and dynamic inherent frequency tests are conducted to assess its dynamic and static performance. Finally, the smart toolholder is tested for accuracy and repeatability in terms of force, vibration, and temperature. Experimental results demonstrate that the smart toolholder accurately captures machining data with a relative deviation of less than 1.5% compared with existing force gauges and provides high repeatability of milling temperature and vibration signals. Therefore, it is a smart solution for machining condition monitoring.
Jin ZHANG , Xinzhen KANG , Zhengmao YE , Lei LIU , Guibao TAO , Huajun CAO . Development and testing of a wireless smart toolholder with multi-sensor fusion[J]. Frontiers of Mechanical Engineering, 2023 , 18(4) : 55 . DOI: 10.1007/s11465-023-0774-y
Ax, Ay, Az | Average values of milling vibration in the x-, y-, and z-direction, respectively |
, , | Force measurement errors in the x-, y-, and z-direction, respectively |
, , | Torque measurement errors in the x-, y-, and z-direction, respectively |
fs | Design frequency of the smart toolholder |
Fhf | Free mode force |
Fhwx, Fhwy | Working mode forces in the x- and y-direction, respectively |
Fp | Perpendicular force |
Fr | Radial force |
Fv | Velocity force |
Fx, Fy, Fz | Forces in the x-, y-, and z-direction, respectively |
, | Maximum and minimum milling force average values among the three measured datasets, respectively |
, , | Kistler’s average values of 100000 consecutive force data points in the x-, y-, and z-direction, respectively |
Smart toolholder’s average value of 100000 consecutive force data points in the z-direction | |
Ktx, Kty, Ktz | Torque stiffness indexes in the x-, y-, and z-direction, respectively |
Kx, Ky, Kz | Stiffness indexes in the x-, y-, and z-direction, respectively |
L | Distance from the tip of the tool to the reference center of the force sensor |
, | Smart toolholder’s average values of 100000 consecutive bending moment data points in the x- and y-direction, respectively |
n | Spindle speed |
p | Number of sampling points of per cutting tooth |
R | Tool radius |
Tmax, Tmin | Milling temperatures during machining |
Tx, Ty, Tz | Torques in the x-, y-, and z-direction, respectively |
vf | Feed speed |
z | Number of cutting teeth |
αe | Radial cut width |
αp | Axial cutting depth |
Measurement bending moment and force error | |
Measurement vibration error | |
Temperature difference | |
, , | Percentage errors in the x-, y- and z-direction, respectively |
θ | Angle between Fr and the x-axis |
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