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Title Dynamometer for cutting force measurement in micro milling
Author Baù, Alessandro
Supervisor Hansen, Hans Nørgaard (Institut for Produktion og Ledelse, Danmarks Tekniske Universitet, DTU, DK-2800 Kgs. Lyngby, Denmark)
Bissacco, Giuliano (Institut for Produktion og Ledelse, Danmarks Tekniske Universitet, DTU, DK-2800 Kgs. Lyngby, Denmark)
Institution Technical University of Denmark, DTU, DK-2800 Kgs. Lyngby, Denmark
Thesis level Master's thesis
Year 2007
Abstract Micro milling is an extremely versatile manufacturing process which allows to produce complex 3 dimensional shapes; its combination with the replication techniques gives great advantage for the mass production of micro and meso components. The selection of cutting parameters cannot be based on the available macro experience for problems due to the limited scalability of the process; thus it should be based on the knowledge of the cutting forces. At the moment reliable, accurate and cost effective dynamometers are not yet available. This thesis deals with the design and construction of a dynamometer for cutting force measurements in micro milling operations. The main challenge is the realization of a measuring instrument characterized by high resonance frequency, high sensitivity, low noise and interfaced with an acquisition system with high sampling rate. After a screening of different possibilities the author decided to exploit the characteristics of a 3 component piezoelectric sensor to develop the dynamometer. The design of the components, which have to satisfied the mentioned requirements, is here presented. After the realization of the static calibration of the dynamometer and an investigation to reduce the noise level affecting the signal, a particular device was developed for the verification of the response of the of measuring device. A series of cutting experiments was performed with different end mill and applying a modular approaches to have reliable data for further comparisons. The micro milling process was realized with a conventional machine tool equipped with an attached high speed spindle. Such system required an accurate control of the axial depth of cut. The attention was focused on the thermal deformation of the machine tool structure and of the high speed spindle. A computerized program was developed for the acquisition of the thermal deformations.
Pages 116
Admin Creation date: 2008-02-08    Update date: 2008-02-08    Source: dtu    ID: 210408    Original MXD