A Dynamical Instrument for Machining Centers

In the program, we will develop a measurement system based on the dynamics of the machining process. This system will use the variation in the forces or accelerations occurring during machining to characterize the mechanisms occurring between the cutter and workpiece. This will provide real time indications of the finish of the surface that is being created, the proximity to the chatter threshold, the presence of a worn, damaged, or loose tool, a loose workpiece, and the adequacy of the coolant flow.

Phase I will demonstrate concept feasibility through laboratory machining tests with instrumented workpieces. The testing will examine the effects of spindle and advance speed and depth of cut on surface finish and proximity of chatter. Phase II will further develop the instrument system, including installing the sensors in the spindle assembly, expanding the measurement capabilities, and achieving real-time measurement.