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The static calibration: is to establish the relation curve and mathematical model between the sensor output voltage and the cutting force by experiment.
Scaling: is the cutting force 00H FFH digital A/D converter after the conversion to the actual value.
The two steps above work finished cutting force before the SCM LED display the actual value of NC lathe. In order to CNC lathe operator for monitoring and management of production.
Since the sensor input and output is linear, so here is the linear scaling transformation, by the following formula to calculate the scale conversion factor.
Y＝(Ymax－Ymin)(X-Nmin)／(Nmax－Nmin)＋Ymin
Type of: The Y parameter measurement; Ymax parameter range maximum value; Ymin parameter range minimum; Nmax A / D conversion Ymax corresponding to the input value; A / D conversion of Nmin to Ymin range starting point after the corresponding input values; X measurement value of A / D conversion Y values can be calculated the scaling transform coefficient.
Here because the sensor measuring range of cutting forces transformation 0 ~ 1500N, its output voltage is 0 ~ 5mV, through the amplifier circuit is 0 ~ 5V, through ADC0809 0 to 255 is converted to digital.
By a linear scaling transformation formula：
Y＝(Ymax－Ymin)(X-Nmin)／(Nmax－Nmin)＋Ymin
Can be calculated：
Y=1500/255*X
So the design of the scale conversion factor 1500/255。
5. Conclusions
In this study, an indirect cutting force measurement method based on frequency analysis is suggested for micro end-milling process monitoring. Two types of sensor systems, an acceleration sensor and current hall sensors, were used. The measured signals were compared with the cutting force com-parents obtained using a micro tool dynamometer at the frequency domain. The calculated correlations showed linearity of 98.0% and 94.5% precision with the use of an acceleration sensor and current hall sensors, respectively.
The results of this research are summarized as follows:
(1) The developed monitoring system using current hall sensors and an acceleration sensor can be used to investigate the required characteristics of a micro machining system and to determine the optimum cutting conditions.
(2) For the purpose of indirect cutting force measurement, the motor currents and acceleration signal can be measured by amplitude variation via frequency analysis.
(3) Analysis using multi-sensors in the micro machining process is a very useful means of obtaining precise results.
Acknowledgment
This research was financially supported by the Ministry of Knowledge Economy (MKE) and the Korean Industrial Tech-neology Foundation (KOTEF) through the Human Resource Training Project for Strategic Technology.
References
[1] J. Chae, S. S. Park and T. Freshet, Investigation of micro-cutting operations, International Journal of Machine tools & Manufacture, 46 (2006) 313-332.
[2] D. W. Cho, S. J. Lee and C. N. Cho, The state of machining process monitoring research in Korea, International Journal of Machine tools & Manufacture, 39 (1999)
[3] M. C. Kang, J. S. Kim and J. H. Kim, A monitoring tech-nique using a multi-sensor in high speed machining, Journal of Materials Processing Technology, 113 (2001) 331-336.
[4] G. D. Kim, W. T. Kwon and C. N. Chu, Indirect Cutting Force Measurement and Cutting Force Regulation Using Spindle Motor Current, Journal of the Korea Society of Pre-cision Engineering, 14 (1997) 15-27.
外文翻译间接测量微型终端切削过程的切削力
【摘要】在这项研究中，霍尔提出了一个有益的间接测量切削力的方法，使用加速度传感器和电流传感器。用高速主轴上的精确的微加工阶段，进行了一系列的实验。高速主轴加速度传感器被安装在主轴头，和电流的霍尔传感器被连接到电机的电流输入电缆。从所获得的结果，刀具齿旋转和电流的幅值的相关性呈线性度为92.0％以上的霍尔传感器的信号的精度，和98.0％的加速度传感器信号pre-隧道切口。即使使用的加速度传感器具有更好的线性度比起那些电流霍尔传感器，信号可以很容易地打颤，例如主轴振动等外部干扰影响。从这个角度看，当前的霍尔传感器可以提供更强大的结果。从这个角度来看，目前霍尔传感器可以应用于更多领域。论文网
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