Skip to main content
SpringerLink
Log in

A multi-sensor integrated smart tool holder for cutting process monitoring

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

As two of the most significant parameters reflecting the cutting process, cutting force, and vibration are often adopted for tool condition monitoring (TCM) which is especially important in modern machining. Hence, various methods and sensors for detecting these two signals have been proposed and developed. In this study, an innovative multi-sensor integrated smart tool holder is designed, constructed, and tested, which is capable of measuring triaxial cutting force, torque, and cutting vibration simultaneously and wirelessly in milling operations. A standard commercial tool holder is firstly modified to integrate six capacitive sensors and an acceleration sensor. All the sensors and other electronics, like data acquisition and transmitting unit, are incorporated into the tool holder as a whole system. The characteristics of the device are then determined by a series of tests. Besides, an effective TCM model is built by fusing the features of cutting force and vibration. Experimental results showed good performance of the proposed system which could support wide and flexible application scenarios.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

References

  1. Teti R, Jemielniak K, O’Donnell G, Dornfeld D (2010) Advanced monitoring of machining operations. CIRP Ann Manuf Technol 59(2):717–739. https://doi.org/10.1016/j.cirp.2010.05.010

    Article  Google Scholar 

  2. Jauregui JC, Resendiz JR, Thenozhi S, Szalay T, Jacso A, Takacs M (2018) Frequency and time-frequency analysis of cutting force and vibration signals for tool condition monitoring. IEEE Access 6:6400–6410

    Article  Google Scholar 

  3. Bhuiyan MSH, Choudhury IA (2014) 13.22 - Review of sensor applications in tool condition monitoring in machining. In: Yilbas SHFB (ed) Comprehensive materials processing. Elsevier. (Reprinted, Oxford, pp 539–569. https://doi.org/10.1016/B978-0-08-096532-1.01330-3

    Chapter  Google Scholar 

  4. Rizal M, Ghani JA, Nuawi MZ, Che Haron CH (2015) Development and testing of an integrated rotating dynamometer on tool holder for milling process. Mech Syst Signal Process 52–53:559–576. https://doi.org/10.1016/j.ymssp.2014.07.017

    Article  Google Scholar 

  5. Totis G, Wirtz G, Sortino M, Veselovac D, Kuljanic E, Klocke F (2010) Development of a dynamometer for measuring individual cutting edge forces in face milling. Mech Syst Signal Process 24(6):1844–1857. https://doi.org/10.1016/j.ymssp.2010.02.010

    Article  Google Scholar 

  6. Ma L, Melkote SN, Morehouse JB, Castle JB, Fonda JW, Johnson MA (2012) Thin-film PVDF sensor based monitoring of cutting forces in peripheral end milling. J Dyn Syst Meas Control 134(5):51014

    Article  Google Scholar 

  7. Ma L, Melkote SN, Castle JB (2014) PVDF sensor-based monitoring of milling torque. Int J Adv Manuf Technol 70(9):1603–1614. https://doi.org/10.1007/s00170-013-5410-2

    Article  Google Scholar 

  8. Luo M, Luo H, Axinte D, Liu D, Mei J, Liao Z (2018) A wireless instrumented milling cutter system with embedded PVDF sensors. Mech Syst Signal Process 110:556–568

    Article  Google Scholar 

  9. Qin Y, Zhao Y, Li Y, Zhao Y, Wang P (2016) A high performance torque sensor for milling based on a piezoresistive MEMS strain gauge. Sensors 16(4):513

    Article  Google Scholar 

  10. Qin Y, Zhao Y, Li Y, Zhao Y, Wang P (2017) A novel dynamometer for monitoring milling process. Int J Adv Manuf Technol 92(5-8):2535–2543. https://doi.org/10.1007/s00170-017-0292-3

    Article  Google Scholar 

  11. Fenghe W, Yuanxiang L, Baosu G, Pengfei Z (2018) The design of force measuring tool holder system based on wireless transmission. IEEE Access 6:38556–38566. https://doi.org/10.1109/ACCESS.2018.2853735

    Article  Google Scholar 

  12. Rizal M, Ghani JA, Nuawi MZ, Haron CHC (2018) An embedded multi-sensor system on the rotating dynamometer for real-time condition monitoring in milling. Int J Adv Manuf Technol 95(1-4):811–823. https://doi.org/10.1007/s00170-017-1251-8

    Article  Google Scholar 

  13. Suprock CA, Fussell BK, Hassan RZ, Jerard RB (2009) A low cost wireless tool tip vibration sensor for milling, Evanston, IL, United states, 2009. Proceedings of the ASME International Manufacturing Science and Engineering Conference, MSEC2008. ASME Foundation, pp 465-474. doi: https://doi.org/10.1115/MSEC_ICMP2008-72492

  14. Nichols JS (2009) Design and application of a wireless torque sensor for CNC milling. In: Master of Science. University of New Hampshire, Durham

    Google Scholar 

  15. Albrecht A, Park SS, Altintas Y, Pritschow G (2005) High frequency bandwidth cutting force measurement in milling using capacitance displacement sensors. Int J Mach Tool Manu 45(9):993–1008. https://doi.org/10.1016/j.ijmachtools.2004.11.028

    Article  Google Scholar 

  16. Wang C, Cheng K, Chen X, Minton T, Rakowski R (2014) Design of an instrumented smart cutting tool and its implementation and application perspectives. Smart Mater Struct 23(3):35019

    Article  Google Scholar 

  17. Liu M, Bing J, Xiao L, Yun K, Wan L (2018) Development and testing of an integrated rotating dynamometer based on fiber Bragg grating for four-component cutting force measurement. Sensors 18(4):1254. https://doi.org/10.3390/s18041254

    Article  Google Scholar 

  18. Xie Z, Lu Y, Li J (2017) Development and testing of an integrated smart tool holder for four-component cutting force measurement. Mech Syst Signal Process 93:225–240. https://doi.org/10.1016/j.ymssp.2017.01.038

    Article  Google Scholar 

  19. Xie Z, Li J, Lu Y (2018) An integrated wireless vibration sensing tool holder for milling tool condition monitoring. Int J Adv Manuf Technol 95(5):2885–2896. https://doi.org/10.1007/s00170-017-1391-x

    Article  Google Scholar 

  20. Shaw MC (2005) Metal cutting principles, 2nd edn. Oxford University Press, New York

    Google Scholar 

  21. IS Organization (1989). Tool life testing in milling—part 2: end milling ISO 8688-2: 1989.

  22. Gao D, Liao Z, Lv Z, Lu Y (2015) Multi-scale statistical signal processing of cutting force in cutting tool condition monitoring. Int J Adv Manuf Technol 80(9-12):1–11

    Article  Google Scholar 

  23. Xie Z, Li J, Lu Y (2018) Feature selection and a method to improve the performance of tool condition monitoring. Int J Adv Manuf Technol 100:3197–3206. https://doi.org/10.1007/s00170-018-2926-5

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Qian Xuesen Laboratory of Space Technology, China Academy of Space Technology, Beijing, 100094, China

    Zhengyou Xie & Xinlong Chen

  2. School of Mechatronics Engineering, Harbin Institute of Technology, Harbin, 150001, China

    Yong Lu

Authors
  1. Zhengyou Xie
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yong Lu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xinlong Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Zhengyou Xie.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Xie, Z., Lu, Y. & Chen, X. A multi-sensor integrated smart tool holder for cutting process monitoring. Int J Adv Manuf Technol 110, 853–864 (2020). https://doi.org/10.1007/s00170-020-05905-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05905-7

Keywords

Search

Navigation