Spindle-Integrated Three-Axis Cutting Force Measurement System for Ultra-Precision Diamond Milling

Area of Science:

• Manufacturing Engineering
• Materials Science
• Mechanical Engineering

Background:

• Ultra-precision diamond milling is essential for creating complex precision components.
• Effective machining process monitoring is key to enhancing product quality.
• Existing methods may lack the precision required for micro-scale manufacturing.

Purpose of the Study:

• To develop and validate a spindle-integrated three-axis cutting force measurement method for ultra-precision diamond milling.
• To enable real-time monitoring and control of the milling process.
• To improve the accuracy and efficiency of precision component manufacturing.

Main Methods:

• Designed a novel spindle-integrated force measurement mechanism with four symmetrically arranged piezoelectric force sensors.
• Performed calibration tests to assess linearity and accuracy (less than 2% deviation).
• Implemented a Wiener filter to mitigate noise from vibrations and inertial forces.

Main Results:

• Achieved precision tool-setting in the Z-direction with accuracy below 100 nm.
• Demonstrated effective detection of cutting forces as low as 50 mN.
• Showcased strong correlation between the developed system and commercial dynamometers.

Conclusions:

• The proposed spindle-integrated force measurement system offers a promising and effective in-process monitoring solution for ultra-precision diamond milling.
• This technology facilitates enhanced machining quality and precision component fabrication.
• The system's ability to detect low forces and its accuracy make it valuable for micro-manufacturing applications.