• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.05a
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• pp.15-16
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• 2006

In-process surface roughness prediction is studied in this research. To implement in-process prediction, spindle displacement is introduced. Machined surface's roughness is assumed to be expressed in terms of spindle displacement. In-process measurement of spindle displacement is conducted using CCDS (cylindrical capacitive displacement sensor). Two prediction models are developed. One is simple linear model between measured surface roughness and values by spindle displacement. The other is multiple regression model including machining parameters like spindle speed, fee rate and radial depth of cut. Relation between machined surface roughness and roughness by spindle displacement are verified.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2001.04a
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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.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.16 no.5
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• pp.108-114
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• 2007

A new cutting force estimating approach and machining state monitoring examples are presented which uses a cylindrical displacement sensor built into the spindle. To identify the tool-spindle system dynamics with frequency up to 2 kHz, a home-built electro-magnetic exciter is used. The result is used to build an algorithm to extract the dynamic cutting force signal from the spindle error motion; because the built-in spindle sensor signal contains both spindle-tool dynamics and tool-workpiece interactions. This sensor is very sensitive and can measure broadband signal without affecting the system dynamics. The main characteristic is that it is designed so that the measurement is irrelevant to the geometric errors by covering the entire circumferential area between the target and sensor. It is also very simple to be installed. Usually the spindle front cover part is copied and replaced with a new one with this sensor added. It gives valuable information about the operating condition of the spindle at any time. It can be used to monitor cutting force and chatter vibration, to predict roughness and to compensate the form error by overriding spindle speed or feed rate. This approach is particularly useful in monitoring a high speed machining process.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.10a
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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.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.13 no.5
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• pp.55-61
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• 2004

Chatter monitoring is also important for realizing an unmanned machining system. while many researches were done on this area, it is still a difficult job to detect very small amplitude amount of chattering. A monitoring system using a capacitive spindle displacement sensor was developed to monitor cutting vibration in turning in this research. The variance of the measured spindle displacement signals using the developed sensor was calculated and utilized to quantify the small vibration in machining. The results were compared with variance obtained using a tool dynamometer. The result showed that the developed system could be utilized in monitoring the subtle changes of cutting vibrations with high sensitivity confidence.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.04a
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• pp.516-522
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• 2003

Monitoring chattering is also important for realizing an unmanned machining system While many researches were done on this area, it is still a difficult job to detect very small amplitude amount of chattering. A monitoring system using a capacitive spindle displacement sensor was developed to monitor cutting vibration in turning in this research. The variance of the measured spindle displacement signals using the developed sensor was calculated and utilized to quantity the small vibration in machining. The results were compared with variance obtained using a tool dynamometer. The result showed that the developed system could be utilized in monitoring the subtle changes of cutting vibrations with high sensitivity confidence.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.17 no.6
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• pp.8-13
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• 2008

At present many research projects on high-speed spindles are being conducted. These projects require a measurement technique which includes heat expansion, vibration and displacement measurement according to angular velocity. This paper presents the development of a measurement system for high-speed spindle displacement. The measurement system is based on $LabView^{(R)}$ and features the following sensors: optical sensor which reacts to the position of a marker on the spindle and enables two Laser Displacement Sensors(LDS). These Laser Displacement Sensors send their data to a DAQ(Data Acquisition Device). It is important that the delay time caused by the response times of the sensors as well as the sampling rate of the DAQ is considered because the spindle revolves at very high speeds.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2004.04a
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• pp.376-380
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• 2004

This paper is to develop an optical ruer displacement sensor for monitoring high speed spindle. Proper magnitude of optical power as well as amplification of output signal are necessary to improve sensitivity of the sensor. In this paper, to meet the need of improvement of the sensor resolution, we choose proper optical power and amplification level through speculating on optical power of a laser diode.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.10a
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• pp.385-389
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• 2003

To make high speed spindle system work properly, sensors with outstanding resolution and dynamic characteristics are essential. An optical fiber displacement sensor is based on simple principles. Electrical signal responds to the optical flux change due to the displacement change between a target and a sensor probe. In this paper, the performance of optical fiber displacement sensor has been investigated according to properties of optical fiber Firstly, optical loss has been measured before and after polishing optical fiber endface. Secondly, allowance of optical fiber bending has been tested. thirdly sensitivity and linear range of the sensor has been found out according to the shape of cross section of optical fiber.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.8
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• pp.886-893
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• 2011

To increase the reliability and positional accuracy of a machine tool, a novel capacitive displacement sensor having a cylindrical shape is presented to measure the axial displacement of a machine tool spindle. Characteristics of the sensor were analyzed by numerical simulation. The sensor was built into a specific machine tool spindle and its performance was experimentally investigated. The accuracy of a thermal error compensation system of a machine tool can be enhanced greatly using proposed sensor.