Upgraded Kalman Filtering of Cutting Forces in Milling

Area of Science:

• Mechanical Engineering
• Signal Processing
• Metrology

Background:

• Advanced piezoelectric dynamometers are crucial for accurate cutting force measurement in high-speed and micro-milling.
• Signal bandwidth limitations, caused by mechanical system dynamics, necessitate effective compensation techniques.
• Existing compensation methods, especially for 3D force correction, often involve complex identification phases.

Purpose of the Study:

• To develop an upgraded Kalman filter for improved input force estimation in piezoelectric dynamometers.
• To extend the operational frequency bandwidth of dynamometers beyond current limitations.
• To enhance the accuracy of cutting force measurement in dynamic machining applications.

Main Methods:

• Conceived a novel upgraded Kalman filter incorporating a more general model of dynamometer dynamics.
• Accounted for the influence of the force application point in the dynamometer model.
• Utilized extended Kalman filtering for input force estimation amidst dynamic disturbances.

Main Results:

• Extended the frequency bandwidth of the piezoelectric dynamometer to over 5 kHz (main directions) and 3 kHz (transverse directions).
• Outperformed existing state-of-the-art Kalman filtering methods in terms of achievable bandwidth.
• Successfully addressed crosstalk disturbances and complex dynamometer dynamics that previously limited bandwidth.

Conclusions:

• The upgraded Kalman filter provides a significant advancement in piezoelectric dynamometer performance.
• This method enables more accurate cutting force measurement at higher frequencies, crucial for advanced milling processes.
• The enhanced bandwidth and accuracy offer substantial benefits for research and industrial applications in precision machining.