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Research Papers

Development of Smart Tooling Concepts Applied to Ultraprecision Machining

[+] Author and Article Information
Chao Wang

Warwick Manufacturing Group (WMG),
International Automotive Research Centre,
The University of Warwick,
Coventry CV4 7AL, UK
e-mail: c.wang.1@warwick.ac.uk

Kai Cheng

Institute of Materials and Manufacturing,
Brunel University London,
Uxbridge, London UB8 3PH, UK
e-mail: kai.cheng@brunel.ac.uk

Richard Rakowski

Institute of Materials and Manufacturing,
Brunel University London,
Uxbridge, London UB8 3PH, UK
e-mail: richard.rakowski@brunel.ac.uk

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO- AND NANO-MANUFACTURING. Manuscript received September 27, 2016; final manuscript received January 12, 2017; published online March 17, 2017. Editor: Jian Cao.

J. Micro Nano-Manuf 5(2), 021003 (Mar 17, 2017) (7 pages) Paper No: JMNM-16-1055; doi: 10.1115/1.4035807 History: Received September 27, 2016; Revised January 12, 2017

This paper presents smart tooling concepts applied to ultraprecision machining, particularly through the development of smart tool holders, two types of smart cutting tools, and a smart spindle for high-speed drilling and precision turning purposes, respectively. The smart cutting tools presented are force-based devices, which allow measuring the cutting force in real-time. By monitoring the cutting force, a suitable sensor feedback signal can be captured, which can then be applied for the smart machining. Furthermore, an overview of recent research projects on smart spindle development is provided, demonstrating that signal feedback is very closely correlated to the drilling through a multilayer composite board. Implementation aspects on the proposed smart cutting tool are also explored in the application of hybrid dissimilar material machining.

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Figures

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Fig. 1

The conventional mechanical collet system with critical components displayed

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Fig. 2

(a) Schematic assembly of the smart tool holder and (b) finite element analysis of the radial displacement of centrifugal arm and the gripping pressure on the drill bit at 20 k rpm spindle speed

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Fig. 3

(a) Torque measurement setup and (b) the relationship between the axial push force and the torque on the static torque testing of the smart tool holder

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Fig. 4

(a) Piezoelectric sensor-based smart cutting tool comprises the single-layer piezoelectric sensor, transmitter, receiver, and data acquisition device and (b) calibration of the piezoelectric sensor-based smart tooling against the dynamometer

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Fig. 5

Fly cutter integrated with the SAW sensor and antenna

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Fig. 6

(a) Experimental setup including the smart fly cutter, the workpiece, the dynamometer, and the interrogation and (b) comparison on the cutting force between the dynamometer and the smart fly cutter

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Fig. 8

Multilayer PCB drilling with the smart high-speed spindle: (a) D1790-08 S (AC motor), (b) drill bit size 0.075–6.35 mm, and (c) drilling through multilayer PCB with a measure of axial load and axial displacement

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Fig. 9

The spatial movement of the drill tip while drilling the multilayer board in real-time

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Fig. 10

The ultra precision high-speed milling machine with the high-speed air spindle

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Fig. 11

Shaft motions with certain speeds (a) general form of whirl generated by static unbalance (cylindrical) and (b) dynamic unbalance (conical)

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