Cutting force reconstruction method based on static bandwidth expansion utilizing acceleration sensors
Mechanical Systems and Signal Processing, vol. 224, pp. 112139
Abstract
The cutting force is the most direct indicator reflecting tool wear and machining quality. However, direct cutting force measurement equipment requires high costs and will alter dynamic performance, making it difficult to apply in actual production. A single accelerometer can reconstruct the high-frequency dynamic alternating current (AC) components, but it is limited by bandwidth and cannot accurately reconstruct the low-frequency static direct current (DC) components. To address the existing problems of inaccurate reconstruction for the DC components, this article proposes a static bandwidth expansion technology (BET) using acceleration sensors with regard to its application in the field of broaching. BET reconstructs the low-frequency DC components of the broaching force using the AC components obtained from acceleration signals and the metal cutting area. The AC components of the broaching force are reconstructed from acceleration signals through double integration, combined with a Kalman filter that incorporates dynamic parameters. The complete broaching force signal can be obtained by fusing the AC and DC components. BET overcomes the problem of low-frequency bandwidth distortion in the accelerometer sensor and successfully expands the low-frequency bandwidth of the accelerometer sensor , achieving the function of reconstructing cutting force with a single accelerometer sensor. This technology is applied in the actual machining process, and the reconstructed broaching force based on BET has a high degree of coincidence with the experimentally obtained broaching force in the time-frequency domain.
Authors 6
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Affiliation as printed
School of Mechatronic Engineering and Automation, Shanghai University, Shangda Road 99, Shanghai 200444, PR China
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Shunqi Zhang corresponding
Affiliation as printed
School of Mechatronic Engineering and Automation, Shanghai University, Shangda Road 99, Shanghai 200444, PR China
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Affiliation as printed
Zhejiang CHR Intelligent Equipment Co., Ltd, Jinyun 321404, PR China
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Shenshun Ying corresponding
Zhejiang University of Technology
Affiliation as printed
Key Laboratory of Special Purpose Equipment and Advanced Processing Technology, Ministry of Education and Zhejiang Province, Zhejiang University of Technology, Liuhe Road 288, Hangzhou 310023, PR China
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Affiliation as printed
Zhejiang CHR Intelligent Equipment Co., Ltd, Jinyun 321404, PR China
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Affiliation as printed
Institute of Structural Mechanics and Lightweight Design, RWTH Aachen University, Aachen 52062, Germany
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