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On the design of a monitoring system for desktop micro-milling machines
by P. Stavropoulos, A. Stournaras, G. Chryssolouris
International Journal of Nanomanufacturing (IJNM), Vol. 3, No. 1/2, 2009
Abstract: A critical issue in micro-milling is the unpredictability of tool life and the premature tool failure. Micro-end-milling is emerging as an important fabrication process. Its benefits include the ability to fabricate micro and meso-scale parts out of a greater range of materials and with more varied geometry than it is possible with lithography and etching. A variety of sensors can be used for capturing the necessary information on micro-machining process. These sensors may vary from encoders, load cells, accelerometers to acoustic emission (AE) sensors. Each sensor type has a main field of application, which depends both on the desired level of precision and the control parameter that must be measured. This paper presents the design philosophy, restrictions and a consideration, of a combinational method for developing a process monitoring system that is capable of monitoring simultaneously the spindle's and tool's condition during micro-milling operations. The design of the monitoring system is based on vibration and AEs caused by the micro-milling process.
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