Machining Tool Measurement Device for Vibration Analysis
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Solution Overview
Problem
Current methods for predicting the dynamic behavior of cutting tools in machining processes are inefficient, requiring physical testing of multiple machine-tool/cutting tool combinations, which leads to loss of production time and is complicated by the mechanical complexity of the system, especially when trying to obtain frequency response functions and stability charts.
Innovation Solution
A measurement device is designed to measure the dynamic response of a cutting tool substructure, allowing for accurate and repeatable measurements by positioning accelerometers relative to a coupling point, facilitating the prediction of vibration performance and frequency response functions, enabling the creation of stability charts for various cutting tools without the need for extensive physical testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical testing of multiple machine-tool/cutting tool combinations is performed to obtain frequency response functions, then measurement accuracy is improved, but production time is lost and device complexity increases
Solution Approach 1:
The cutting tool is divided into two separate parts: a measurement device (tool holder without tool tip) and a tool tip. The measurement device is used repeatedly to obtain frequency response functions of the machine-tool assembly, while different tool tips can be added as needed. This segmentation eliminates the need to re-measure the entire tool assembly for each tool tip change, significantly reducing production time while maintaining measurement accuracy.
Solution Approach 2:
Instead of physically testing each complete machine-tool/cutting tool combination, the patent uses a standardized measurement device that represents the tool holder portion. Frequency response functions are obtained using this copy/representation, and then combined with models of actual tool tips to predict the dynamic behavior of complete tool assemblies, avoiding time-consuming physical testing of each combination.
2Measurement precision
If physical testing of multiple machine-tool/cutting tool combinations is performed, then measurement accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The system is segmented into a reusable measurement device (tool holder with standardized interface) and variable tool tips. The measurement device contains all necessary measurement components (accelerometers, excitation means) in a fixed configuration, eliminating the need for complex reconfiguration when testing different tool tips, thus reducing overall device complexity while maintaining measurement accuracy.
Solution Approach 2:
The measurement device is designed with a universal interface that can accommodate multiple different tool tips. The same measurement device can be used to obtain frequency response functions for various cutting tools by simply changing the tool tip, making the system multi-functional and reducing the need for multiple specialized testing setups.
3Measurement precision
If complete machine tool structure is modeled to predict dynamic behavior, then prediction accuracy is improved, but modeling difficulty increases due to mechanical complexity
Solution Approach 1:
The complete machine tool system is segmented into measurable components (machine-tool assembly frequency response functions obtained through physical testing) and tool tip models (created through CAD/FEA). This segmentation allows accurate modeling of the complex machine tool structure by combining experimentally verified data with simplified tool tip models, reducing overall modeling complexity while maintaining prediction accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for cost-efficient, accurate prediction of dynamic behavior and stability in cutting tools, reducing the risk of chatter vibrations and improving machining efficiency by enabling the use of modeled data to determine stable operational parameters.
Implementation Method 1
a plurality of seats for receiving one accelerometer each, for measuring a response of the received mechanical excitation
Data Source
AI summary
A measurement device for a chip removing machine, and methods of obtaining frequency response functions, obtaining stability charts and selecting operational parameters of a chip removing machining tool are disclosed. The device includes an engagement portion at the rear end for engagement with the machine and a measurement portion at the front end. The measurement portion is without a tool tip and includes a planar front end surface perpendicular to the centre axis. The front end surface has a coupling point aligned with the centre axis for receiving mechanical excitation. The front end surface further includes a plurality of seats for receiving one accelerometer each for measuring a response of the received mechanical excitation. When an accelerometer is received in one of the seats, and abutts against three contact surfaces thereof, it is positioned and oriented three dimensionally and around three axes of rotation in relation to the coupling point.