Tool Holder Sensor Module for Direct Cutting Tool Deflection Sensing
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Solution Overview
Problem
Existing methods for monitoring machining processes, such as those using strain sensors on tool holders, are inadequate for accurately measuring tool tip deflection and cutting forces due to calibration complexities and uncertainties in determining process parameters.
Innovation Solution
A sensor module with position sensors radially spaced from the cutting tool's axial portion, allowing direct measurement of deflection and cutting forces, which can be used to determine tool tip deflection and provide accurate process parameters for machining processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If strain sensors are mounted on the tool holder to measure cutting forces, then process monitoring is enabled, but measurement precision deteriorates due to system stiffness and inertia changes at the interface
Solution Approach 1:
The patent introduces a sensor module as an intermediary component between the tool holder and the cutting tool. This sensor module includes strain sensors that are integrated into a dedicated mounting structure with known stiffness characteristics, serving as a mediator that isolates the measurement system from the variable interface conditions between the tool holder and cutting tool. The sensor module acts as a standardized interface that eliminates the need for complex calibration of the tool holder-cutting tool interface.
Solution Approach 2:
The patent changes the measurement parameters by using strain sensors to measure strain in the sensor module, which is then converted to cutting forces through a calibrated relationship. The sensor module is designed with specific geometric and material parameters that establish a known relationship between strain and force, allowing accurate force measurement without direct measurement at the tool holder-cutting tool interface.
2Measurement precision
If strain sensors on the tool holder are used to determine tool tip deflection, then deflection can be calculated, but measurement precision deteriorates due to the need for mathematical models and calibration
Solution Approach 1:
The sensor module serves as an intermediary that directly measures strain at a location where the relationship to tool tip deflection is well-defined and can be calibrated once. This eliminates the need for complex mathematical models that would be required if sensors were mounted on the tool holder, as the sensor module's rigid connection to the cutting tool creates a direct mechanical relationship between sensor location and tool tip position.
Solution Approach 2:
The sensor module is pre-calibrated to establish the relationship between measured strain and tool tip deflection before use. This preliminary calibration action eliminates the need for complex mathematical modeling and real-time calibration during operation, as the geometric and stiffness parameters of the sensor module are fixed and known.
3Reliability
If strain sensors are integrated into the tool holder, then process parameters can be measured, but manufacturing precision deteriorates due to the need for extensive calibration
Solution Approach 1:
The sensor module acts as an intermediary component that is manufactured with precise, known geometric and material properties. This standardized intermediary component eliminates the need for extensive calibration of each tool holder, as the sensor module itself provides a stable, repeatable measurement platform with characteristics that are controlled during manufacturing rather than requiring post-manufacturing calibration.
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
Enables precise determination of tool tip deflection and cutting forces, improving the accuracy of process monitoring and enabling real-time feedback for optimizing machining processes.
Implementation Method 1
the position sensor is located radially spaced from the axial portion of the cutting tool for measuring deflection of the cutting tool with respect to the rest position
Data Source
AI summary
A sensor module for a tool holder for a cutting tool, such that when the sensor module is arranged to the tool holder having a cutting tool connected thereto, an axial portion of the cutting tool is positionable in a predefined rest position with respect to the sensor module. The sensor module includes at least one position sensor, wherein, when the sensor module is arranged to the tool holder having a cutting tool connected thereto, the position sensor is located radially spaced from the axial portion of the cutting tool for measuring deflection of the cutting tool with respect to the rest position. The disclosure further relates to a tool holder, a cutting tool, a cutting assembly, and a method for measuring deflection of a cutting tool.