Sensorized Rotating Tool for Accurate Cutting Resistance Measurement
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Solution Overview
Problem
Existing technologies face challenges in accurately measuring the state of machining by cutting tools due to difficulties in calculating rotary cutting resistance and displacement, which are influenced by changes in the spindle and tool holder characteristics.
Innovation Solution
The solution involves attaching acceleration and strain sensors to the rotating tool, allowing for precise measurement of strain and acceleration to calculate rotary cutting resistance and displacement, independent of changes in the spindle and tool holder characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are attached to the tool holder or spindle, then machining state can be measured, but measurement accuracy deteriorates due to changes in spindle and tool holder characteristics
Solution Approach 1:
The patent extracts the sensors from the tool holder or spindle and relocates them directly to the rotating tool (milling cutter). This extraction eliminates the interference of spindle and tool holder characteristic changes, allowing direct measurement of the tool's actual state during machining operations.
Solution Approach 2:
The rotating tool serves as an intermediary carrier for the sensors. By mounting acceleration and strain sensors directly on the tool, the system creates a direct measurement path from the cutting edge to the sensors, bypassing the tool holder and spindle that introduce measurement errors.
2Measurement precision
If sensors are attached to the rotating tool, then measurement accuracy improves, but device complexity increases
Solution Approach 1:
The rotating tool is given multiple functions: it performs its primary cutting function while simultaneously serving as a mounting platform for sensors. This multi-functionality eliminates the need for separate sensor mounting structures, reducing overall device complexity while maintaining measurement accuracy.
Solution Approach 2:
The patent merges the sensor mounting function with the rotating tool structure itself. Instead of adding separate mounting hardware, the sensors are integrated directly onto the tool body, combining measurement and cutting functions into a single unified system.
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 enables accurate calculation of rotary cutting resistance and detection of tool wear, even with changes in the spindle and tool holder, enhancing machining state measurement accuracy.
Implementation Method 1
acceleration sensors 14 attached to the shank portion 11, based on measurement results of the acceleration sensors 14, physical quantities such as displacement amounts at attaching positions of the acceleration sensors 14 including displacement amounts of the tool holder 210, and a spindle 220 that applies a rotational force to the tool holder 210 in the machine tool 202, and a rotary cutting resistance that the shank portion 11 receives from a rotary cutting object
Implementation Method 2
strain sensors 19 attached to the shank portion 11, based on measurement results of the strain sensors 19, physical quantities such as a rotary cutting resistance and a deformation amount of the shank portion 11
Data Source
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AI summary
A rotating tool according to an aspect of the present disclosure is a rotating tool used in a state held by a tool holder, and the rotating tool includes a shaft portion having an end attached to the tool holder, a blade attaching portion or a blade portion provided at an end of the shaft portion opposite to the end, and a plurality of sensors attached to the shaft portion, and the plurality of sensors include an acceleration sensor and a strain sensor.