Three-Dimensional Displacement Measurement of Micro-Milling Tool Based on Fiber Array Encoding

Area of Science:

• Mechanical Engineering
• Optoelectronics
• Metrology

Background:

• Micro-milling tool vibration significantly impacts tool life, machining precision, and efficiency.
• Traditional multi-dimensional vibration measurement methods face online measurement challenges.
• Chaotic vibration is a fundamental issue limiting micro-milling advancements.

Purpose of the Study:

• To develop a novel online multi-dimensional vibration measurement method for micro-milling tools.
• To overcome the limitations of traditional vibration measurement techniques.
• To enhance machining efficiency and accuracy in micro-milling processes.

Main Methods:

• Proposed a three-dimensional (3D) measurement method based on multi-fiber array coding.
• Converted tool spatial motion into an optical coding array decoding process.
• Designed a 6 × 6 optical fiber array and a 3D motion platform for verification.

Main Results:

• Achieved a measurement accuracy of 1 µm for the micro-milling tool.
• Reported maximum linear errors of 1.5% (x-axis), 2.58% (y-axis), and 2.43% (z-axis).
• Demonstrated a maximum measurement error of 3.4% for tool spatial position within a 100 µm³ space.

Conclusions:

• The developed multi-fiber array coding system provides a new approach for online micro-milling tool vibration measurement.
• The system offers unique coding characteristics for precise tool positioning.
• This innovation offers a new realization means for improving micro-milling processes.