Design Optimization of a Compact Double-Ended-Tuning-Fork-Based Resonant Accelerometer for Smart Spindle...

Area of Science:

• Mechanical Engineering
• Sensor Technology
• Manufacturing Science

Background:

• Accelerometers are crucial for monitoring machining processes and detecting chatter, but traditional sensors are often too large for direct integration.
• Existing accelerometers can be obstruct cutting processes or fail to capture accurate vibration signals due to placement limitations.

Purpose of the Study:

• To propose a compact, wide-bandwidth resonant accelerometer for embedding within high-speed spindles.
• To enable real-time chatter monitoring and prediction for improved manufacturing efficiency.

Main Methods:

• Designed a resonant accelerometer using a double-ended tuning fork (DETF), proof mass, and support beam.
• Utilized the resonance frequency shift of the DETF in response to out-of-plane accelerations for sensing.
• Employed commercially available quartz tuning forks (QTFs) with electrodes for symmetric-mode excitations.
• Conducted theoretical modeling and finite element analysis for design optimization.

Main Results:

• The proposed accelerometer has a compact size of 9.76 mm × 4.8 mm × 5.5 mm.
• Achieved a simulated sensitivity of 0.94 Hz/g and a simulated working bandwidth of 3.5 kHz.
• The design offers low noise and a wide operation bandwidth via frequency modulation.

Conclusions:

• The developed compact resonant accelerometer is suitable for in-situ chatter detection within high-speed spindles.
• This technology is expected to significantly benefit chatter detection and support intelligent manufacturing.
• The sensor's small size and wide bandwidth address limitations of conventional accelerometers in machining applications.