 Abstract
The primary objective of this research is to improve dimensional tolerances and reduce total manufacturing time of precision milling operations through the implementation of force-feedback machining. Force-feedback machining consists of using real-time force measurement integrated with high bandwidth actuation to provide active error compensation of tool deflection. This research focuses on the development and implementation force-feedback machining using miniature (< 1 mm diameter) ball end mills. Research Method The research has been divided into four main components:
• Development of real-time on spindle cutting force measurement, separating the spindle’s dynamic response and determination of the input cutting force
• Design of a two-axis spindle actuator with adequate stiffness and frequency response for use in a milling application
• Control of system dynamics of two-input two-output piezo actuated spindle
• Integration of real time cutting force measurement and two-axis spindle actuation to provide real time force feedback compensation of tool deflection errors Results Real-time on spindle cutting force measurements were achieved by mapping the dynamic response of the spindle assembly as a function of cutting speed and dividing out the effects of the spindle's dynamic response. A two-axis piezo actuated spindle micropositioner has been designed and fabricated to provide means of positioning the tool for error compensation. Bench testing and control of the
spindle actuator is currently in development, to be followed by the implementation of real-time force feedback machining. Supporting Materials - ASPE Poster (PowerPoint, 1.77 Mb)
The following faculty, students, and PEC affiliates are involved in this project:
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