• Journal of Mechanical Science and Technology
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• v.19 no.12
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• pp.2205-2212
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• 2005

In this paper, the cutting torque of a CNC machine tool during machining is monitored through the internet. To estimate the cutting torque precisely, the spindle driving system is divided into two parts: electrical induction motor part and mechanical part. A magnetized current is calculated from the measured three-phase stator currents and used for the total torque estimation generated by a spindle motor. Slip angular velocity is calculated from the magnetized current directly, which gets rid of the necessity of a spindle speed sensor. Since the frictional torque changes according to the cutting torque and the spindle rotational speed, an experiment is adopted to obtain the frictional torque as a function of the cutting torque and the spindle rotation speed. Then the cutting torque can be calculated by solving a $2^{nd}$ order difference equation at a given cutting condition. A graphical programming method is used to implement the torque monitoring system developed in this study to the computer and at the same time monitor the torque of the spindle motor in real time through the internet. The cutting torque of the CNC lathe is estimated well within an about $3\%$ error range in average in various cutting conditions.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.12
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• pp.222-229
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• 1999

In order to regulate cutting torque in milling, monitoring system should be set to a certain threshold. Radial immersion ratio is an important factor to determine the threshold and should be estimated in process for automatic regulation. In this paper, on-line estimation of the radial immersion ration using spindle motor current in face milling is presented. When a tooth finishes sweeping, a sudden drop of cutting torque occurs. This torque drop is equal to cutting torque acting on a single tooth at the swept angle of cut and can be acquired form cutting torque signals. Average cutting torque per revolution can also be calculate form cutting torque signals. The ratio of cutting torque acting on a single tooth at the swept angle of cut to the average cutting torque per revolution is a function of the swept angle of cut and the number of teeth. Using the magnitude of this ratio, the radial immersion ratio is estimated. Identical algorithm is adopted to estimate the immersion ratio based on the spindle motor current measurement. The experiments performed under different cutting conditions show that the radial immersion ratio can be estimated within 10% error range by the proposed method using spindle motor current.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.9 no.6
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• pp.57-64
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• 2000

In order to regulate cutting torque in milling, monitoring system should be set to a certain threshold. Radial immersion ratio is an important factor to determine the threshold and should be estimated in process for automatic regulation. In this paper, on-line estimation of the radial immersion ratio using spindle motor current in face milling is presented. When a tooth finishes sweeping, a sudden drop of cutting torque occurs. This torque drop is equal to the cutting torque acting on a single tooth at the swept angle of cut and can be acquired from cutting torque signals. Average cutting torque per revolution can also be calculated from cutting torque signals. The ratio of cutting torque acting on a single tooth at the swept angle of cut to the average cutting torque per revolution is a function of the swept angle of cut and the number of teeth. Using the magnitude of this ratio, the radial immersion ratio is estimated. Identical algorithm is adopted to estimate the immersion ratio based on the spindle motor current measurement. The experiments performed under different cutting conditions show that the radial immersion ratio can be estimated within 10% error range by the proposed method using spindle motor current. Varying immersion ratio is also estimated well using the presented algorithm.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.1088-1094
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• 1997

An indirect cutting torque and cutting force estimation method is presented. This method uses a time-domain model between the spindle motor power, which calculated form measured spindle motor current and voltage. Spindle motor power is linear with cutting torque in this model. The cutting force is proportional to the cutting torque. Using trial cut, parameters are determined. Static sensitivity is suitable for various cutting conditions. The presented method is verified under several cutting tests on the CNC horizontal machining center.

• Journal of the Korean Society for Precision Engineering
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• v.18 no.8
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• pp.107-115
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• 2001

Drilling torque was measured indirectly using the spindle motor current and controlled in real time through feedrate manipulation in a machining center. The PID controller designed in the previous paper was applied to drilling torque control. A series of cutting experiments were performed for various cutting conditions. Experimental results showed that the drilling torque was well regulated at a given reference level by feedrate manipulation in all cutting conditions. The increase in the cutting torque and temperature according to the increase in machining depth was suppressed and the risk of the drill failure and the drill flank wear were reduced remarkably through cutting torque control. Moreover, the suggested cutting torque control system doesn\`t disturb the cutting process and is practical for industrial environment. Therefore, the proposed culling torque control system will contribute to productivity improvement in drilling process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.243-246
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• 2000

Productivty of tapping has been increasing through the tcchnological advances in synchronization between spindle rotation and feed motion even in the high spindle speed. However, not much researches have been conducted about tapping process because its complicate cutting mechanism. In order ta investigate the characteristics of the tapping process, this paper concentrates on the analysis of curting torque behavior during one cycle of lapping. As one completc thread is performed through the whole chamfer ercuttlng, cutting torque increases highly in chamfer cutting, but smaothly in full thread cutting Functioning of the threads guide. Cutting torque in backward cutting is smaller than in Sorwerd cutting due to only friction farce in against between the tool and workpiece. And torque behavior of a periodic Sine ripple-mark was identified during one revolution of a tap.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.10a
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• pp.18-23
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• 2002

In this paper, The torque of CNC spindle motor during machining is estimated without speed measuring sensor. The CNC spindle system is divided into two parts, the induction spindle motor part and mechanical part. In mechanical part the variation of the frictional force due to the increment of the cutting torque and the effect of damping coefficient is investigated. Damping coefficient is found to be a function of spindle speed and not influenced by the weight of the load, while frictional force is a function of both the cutting torque and spindle speed. Experimental formulars are drawn for damping coefficient as a function of spindle speed and frictional force as a function of both cutting torque and spindle speed respectively, to estimate the cutting torque accurately. Graphical programming is used to implement the suggested algorithm, to monitor the torque of an induction motor in real time. Torque of the spindle induction motor is well monitored with 3% error range under various cutting conditions.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.555-559
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• 2001

Feed and spindle motor currents are used toi monitor the cutting process practically. The sensitivity of spindle drive system is lower than that of feed drive system, but the cutting torque is represented well by the spindle motor current. During multi-axis cutting, it is difficult to calculate the resultant cutting force using feed motor currents, because each feed force is reflected by each axis feed motor current with different time delay. It is also difficult to compensate the frictional torque using the feed motor current, because the magnitude of the frictional torque is dependent of the feedrate, table position, and cutting direction. On the other hand, cutting torque can be estimated well using spindle motor current which is independent of the cutting direction.

• Tribology and Lubricants
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• v.28 no.3
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• pp.130-135
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• 2012

This study presents a new methodology for realtime tool breakage detection by sensor fusion concept of two hall sensor and an acoustic emission (AE) sensor. Spindle induction motor torque of CNC Lathe during machining is estimated by two hall sensor. Estimated motor torque instead of a tool dynamometer was used to measure the cutting torque and tool breakage detection. A burst of AE signal was used as a triggering signal to inspect the cutting torque. A significant drop of cutting torque was utilized to detect tool breakage. The algorithm was implemented on a NI DAQ (Data Acquisition) board for in-process tool breakage detection. The result of experiment showed an excellent monitoring capability of the proposed tool breakage detection system. This system is available tool breakage monitoring through internet also provides this system's user with current cutting torque of induction motor.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.9
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• pp.2234-2241
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• 1993

The torque variation in drilling process represents the problems of the efficient and stable machining. In order to cope with them, the active control method is adopted to drill the workpiece under the constant cutting torque though the cutting stiffness of the workpiece or the diameter of the drill bit changes. The cutting process is modeled in the geometric viewpoint related with the feed and the number of cutting lips. And the dynamic model is approximated to the first order system for the purpose of control. The adaptive PI control is used in computer simulations and experiments. The results of the study show the validity of the drilling method with torque control.