• 한국정밀공학회지
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• 제12권3호
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• pp.130-143
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• 1995

This paper presents a new methodology for on-line tool breadage detection by sensor fusion of an acoustic emission (AE) sensor and a built-in force sensor. A built-in piezoelectric force sensor, instead of a tool dynamometer, was used to measure the cutting force without altering the machine tool dynamics. The sensor was inserted in the tool turret housing of an NC lathe. FEM analysis was carried out to locate the most sensitive position for the sensor. A burst of AE signal was used as a triggering signal to inspect the cutting force. A sighificant drop of cutting force was utilized to detect tool breakage. The algorithm was implemented on a DSP board for in-process tool breakage detection. Experiental works showed an excellent monitoring capability of the proposed tool breakage detection system.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2004년도 추계학술대회 논문집
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• pp.485-489
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• 2004

Cutting force is important to understand cutting process in milling. To measure cutting force, tool dynamometer is widely used but it is hard to apply in workshop condition. Cutting force measurement which doesn't affect cutting process is needed. Using relations between cutting force and spindle displacement, cutting force can be predicted. Cylindrical capacitive sensor was used to measure spindle displacement during cutting. And signals from tool dynamometer collected to compare with spindle displacement. The result shows spindle displacement has a linear relation with cutting force. Using this result, a simple method to predict cutting force could be applied at workshop condition.

• 한국정밀공학회지
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• 제15권11호
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• pp.9-20
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• 1998

In recent manufacturing process, the increase of productivity has been attempted by reducing machining time with the increase of cutting force. However, the excessive increase of cutting force can cause tool breakage and have a bad effect on both manufacturing machine and workpiece. Thus, it is necessary to estimate and control the cutting force in real time during the process. In this study, use of disturbance observer is proposed for the indirect cutting force estimation. The estimated cutting force is used for the real-time control of feedrate, making the actual cutting force follow the reference force command. Since the suggested method does not need an expensive sensor like a dynamometer, the method is expected to be used practically. Since the actual cutting force follow the reference force, resulting the reducing of the machining time the increase of productivity are also expected, and the quality of cutting surface has been improved due to the adjusted feedrate. Besides, an actual constant cutting force guarantees the prevention of tool breakage. To show the effectiveness of the suggested cutting force control method, an experimental setup has been made without sensor and applied to several workpieces. Experiments show that the suggested method is effective to cutting force control of a CNC machining center.

• 제어로봇시스템학회:학술대회논문집
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• 제어로봇시스템학회 1997년도 한국자동제어학술회의논문집; 한국전력공사 서울연수원; 17-18 Oct. 1997
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• pp.660-663
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• 1997

In recent manufacturing process, the increase of productivity is required by reducing machining time with the increase of cutting force. However, the excessive increase of cutting force can cause tool breakage, and have a bad effect on both the manufacturing machine and the workpiece. Thus, it is necessary to estimate and control cutting force in real time during the process. In this study, use of disturbance observer is proposed for the indirect cutting force estimation. The estimated cutting force is used for the real time control of feedrate, making the actual cutting force follow the reference force command. Since the suggested method does not need an expensive sensor like a dynamometer, the method is expected to be used practically. By reducing the machining time resulting from making the actual cutting force follow the reference force, the increase of productivity are also expected, and the quality of cutting surface has been improved due to the adjusted feedrate. Besides, an actual constant cutting force guarantees the prevention of tool breakage. To show the effectiveness of the suggested cutting force control method, an experimental setup has been made without the force sensor, applied to several workpieces. Experiments show that the suggested method is superior to the conventional method operated by constant feedrate.

• 한국공작기계학회:학술대회논문집
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• 한국공작기계학회 2001년도 춘계학술대회 논문집(한국공작기계학회)
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• pp.89-94
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• 2001

A cylindrical capacitance-type spindle displacement sensor was designed and tested in the hard turning as a way to develop a sensor that can estimate cutting forces without using a tool dynamometer. The displacement sensor was installed between the face of spindle cover and the chucking element, and measured pure radial motion of the spindle. Ceramic inserts and tool steel workpieceof 65 Rc were used during the hard turning tests. The signals from the sensor showed the same pattern of cutting force variations as those from the tool dynamometer. The research results showed that the developed sensor could be utilized as an effective and cheap on-line sensing device to estimate cutting forces.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1992년도 추계학술대회 논문집
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• pp.344-348
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• 1992

This paper presents a new methodology for on-line tool breakage detection by sensor fusion concept of an acoustic-emission (AE) sensor. A built-in piezoelectric force sensor was used to measure cutting force instead of a tool dynamometer to preserve the machine tool dynamics. he sensor was inserted in the tool turret housing of an NC lathe. FEM analysis was carried out to locate the most sensitive position for the sensor. When a tool is broken, the explicit changes of signals' pattern take place. A burst-type AE signal increases abruptly. Followingly, a cutting force drops significantly. Therefore a burst of AE signal is used as a triggering signal to inspect the following cutting force. Significant drop of cutting force is utilized to detect tool breakage. The algorithm was implemented in a DSP board for in-process tool breakage detection. The proposed monitoring system was capable of a good applicable tool breakage detection.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1996년도 추계학술대회 논문집
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• pp.200-205
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• 1996

Recently, in order to achieve high flexibility of manufacture, monitoring and control strategies cf a new type have been developed. Since the generation of built-up edge on the cutting tool damages the surface finish of the workpiece, the monitoring system of built-up edge is an important process monitoring. In this study, the analyzing methods of cutting force signal to detect the built-up edge during cutting process are described. The cutting force signals are analyzed using the mean, standard deviation and mean to standard deviation of this cutting signals. We can obtain the guide to detect the built-up edge during turning process.

• 한국정밀공학회지
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• 제14권7호
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• pp.67-72
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• 1997

Recently, in order to achieve high flexibility of manufacture, monitoring and control strategies of a new type have been developed. Since the generation of built-up edge on the cutting tool damages the surface finish of the workpiece, the monitoring system of built-up edge is an important process monitoring. In this study, the analyzing methods of cutting force signal to detect the built-up edge during cutting process are described. The cutting force signals are analyzed using the mean, standard deviation and mean to standard deviation of this cutting signals. We can obtain the guide to detect the built-up edge during turning process.

• 한국공작기계학회논문집
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• 제11권2호
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• pp.17-23
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• 2002

A cylindrical capacitance-type spindle displacement sensor was developed and its effectiveness as a system to monitor cutting forces during hard turning was tested in this research. The sensor was installed between the face of spindle cover and the chucking element and measured pure radial motion of the spindle under the condition with presence of roundness error at measured surface. To prove the effectiveness of the developed system hard aiming tests using ceramic inserts and tool steel as workpiece were conducted. The workpiece was hardened up to 65 Rc. The variations of pure radial motion of the spindle ware measured during the cutting tests. The signals from the sensor showed the same pattern of cutting force variations from the tool dynamometer due to the progress of tool wear. As the flank wear of the ceramic tool increased both static component of cutting forces and the amount of center shift of spindle orbit increased, Results from the research showed that the developed sensor could be utilized as an effective and cheap on-line sensing device to monitor cutting conditions and tool performance in the un-manned machining center.

• 한국기계가공학회지
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• 제18권6호
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• pp.26-32
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• 2019

Ball end mills used for high-speed and high-precision machining require longer machining time than flat end mills or face cutters, since the tool diameter is limited and the rigidity is reduced by the characteristics of the tool's cutting edge: at the top end of the tool, the cutting speed approaches zero and hardly removes any material. Because there is little material removal at the top end of the ball end mill, the outer cutting edge performs the majority of the work; this irregular cutting force deforms the tool and shortens its life. In this study, we attached an eddy-current sensor to a tool to measure the deformation from the cutting force and we used a tool dynamometer to measure the cutting force. We found that the change in cutting force is dependent on the change in feed rate during square-shaped processing and, as the feed rate is accelerated, the cutting force also increases. Higher cutting forces increase tool deformation.