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以带有悬臂梁的聚偏二氟乙烯薄膜传感器用于薄壁工件铣削的实时挠度监测为例

Real-Time Deflection Monitoring for Milling of a Thin-Walled Workpiece by Using PVDF Thin-Film Sensors with a Cantilevered Beam as a Case Study.

作者信息

Luo Ming, Liu Dongsheng, Luo Huan

机构信息

Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of Education, Northwestern Polytechnical University, Xi'an 710072, China.

出版信息

Sensors (Basel). 2016 Sep 10;16(9):1470. doi: 10.3390/s16091470.

DOI:10.3390/s16091470
PMID:27626424
原文链接:https://pmc.ncbi.nlm.nih.gov/articles/PMC5038748/
Abstract

Thin-walled workpieces, such as aero-engine blisks and casings, are usually made of hard-to-cut materials. The wall thickness is very small and it is easy to deflect during milling process under dynamic cutting forces, leading to inaccurate workpiece dimensions and poor surface integrity. To understand the workpiece deflection behavior in a machining process, a new real-time nonintrusive method for deflection monitoring is presented, and a detailed analysis of workpiece deflection for different machining stages of the whole machining process is discussed. The thin-film polyvinylidene fluoride (PVDF) sensor is attached to the non-machining surface of the workpiece to copy the deflection excited by the dynamic cutting force. The relationship between the input deflection and the output voltage of the monitoring system is calibrated by testing. Monitored workpiece deflection results show that the workpiece experiences obvious vibration during the cutter entering the workpiece stage, and vibration during the machining process can be easily tracked by monitoring the deflection of the workpiece. During the cutter exiting the workpiece stage, the workpiece experiences forced vibration firstly, and free vibration exists until the amplitude reduces to zero after the cutter exits the workpiece. Machining results confirmed the suitability of the deflection monitoring system for machining thin-walled workpieces with the application of PVDF sensors.

摘要

薄壁工件，如航空发动机的整体叶盘和机匣，通常由难切削材料制成。其壁厚非常小，在动态切削力作用下铣削过程中容易发生挠曲，导致工件尺寸不准确且表面完整性差。为了解加工过程中工件的挠曲行为，提出了一种新的实时非侵入式挠曲监测方法，并对整个加工过程不同加工阶段的工件挠曲进行了详细分析。将薄膜聚偏二氟乙烯（PVDF）传感器附着在工件的非加工表面，以复制动态切削力激发的挠曲。通过测试校准监测系统的输入挠曲与输出电压之间的关系。监测到的工件挠曲结果表明，在刀具切入工件阶段工件会经历明显振动，并且通过监测工件挠曲可以很容易地跟踪加工过程中的振动。在刀具退出工件阶段，工件首先会经历受迫振动，并且在刀具退出工件后会存在自由振动，直到振幅降至零。加工结果证实了应用PVDF传感器的挠曲监测系统适用于加工薄壁工件。

https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/238662be7e0a/sensors-16-01470-g013.jpg
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https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/e04c1e6b90d7/sensors-16-01470-g006.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/077fbd90cf70/sensors-16-01470-g007.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/d2375c1611f7/sensors-16-01470-g008.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/10bf233c42d4/sensors-16-01470-g009.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/f2ceb99e5ead/sensors-16-01470-g010.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/7dfd7167b882/sensors-16-01470-g011.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/9293a09a4884/sensors-16-01470-g012.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/238662be7e0a/sensors-16-01470-g013.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/69a932ed51d9/sensors-16-01470-g001.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/8b41c7b4c3f3/sensors-16-01470-g002.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/b76a6df66cfb/sensors-16-01470-g003.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/9dce9df52d0a/sensors-16-01470-g004.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/93bd88d950ab/sensors-16-01470-g005.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/e04c1e6b90d7/sensors-16-01470-g006.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/077fbd90cf70/sensors-16-01470-g007.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/d2375c1611f7/sensors-16-01470-g008.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/10bf233c42d4/sensors-16-01470-g009.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/f2ceb99e5ead/sensors-16-01470-g010.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/7dfd7167b882/sensors-16-01470-g011.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/9293a09a4884/sensors-16-01470-g012.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/2557/5038748/238662be7e0a/sensors-16-01470-g013.jpg

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