Title: On the design of a monitoring system for desktop micro-milling machines

Authors: P. Stavropoulos, A. Stournaras, G. Chryssolouris

Addresses: Laboratory for Manufacturing Systems and Automation, Department of Mechanical Engineering and Aeronautics, University of Patras, Patras 26110, Greece. ' Laboratory for Manufacturing Systems and Automation, Department of Mechanical Engineering and Aeronautics, University of Patras, Patras 26110, Greece. ' Laboratory for Manufacturing Systems and Automation, Department of Mechanical Engineering and Aeronautics, University of Patras, Patras 26110, Greece

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.

Keywords: desktop micromilling; condition monitoring; vibration emissions; acoustic emission; AE; end milling; micromachining; tool life; tool failure; process monitoring.

DOI: 10.1504/IJNM.2009.027049

International Journal of Nanomanufacturing, 2009 Vol.3 No.1/2, pp.29 - 39

Available online: 13 Jul 2009 *

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