Skip to main content
SpringerLink
Log in

Design and analysis of a prototypical sensory Z-slide for machine tools

  • Machine Tool
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

Due to the advancements in high speed and high performance cutting, further improvements of machine component design and process monitoring are necessary. For this purpose, new machine components with process monitoring capabilities have to be developed. In this paper, a new spindle carrying Z-slide for a 5-axis machining center with integrated sensing capabilities for process monitoring is presented. First, the overall system design is described. The sensing capabilities to enable process monitoring are realized by application of a micro-strain gauges network on to the structure of the slide. The optimal sensor positions are computed by application of a special sensor placement algorithm. The prototype of the slide has been built up to investigate the system behavior. The electronic system of the prototype to realize the signal amplification and the communication via an industrial bus are presented. Furthermore, the results of the system analysis of the prototype are described. Because the sensor amplitudes, which can be monitored by strain gauges on stiff structures, are generally small, a method to increase these amplitudes by use of the notch effect and new micro-strain sensors is discussed. With this method, the signal amplitudes can be increased significantly, without degrading the stiffness noticeably. At the end of the paper a method to manufacture notches in the prototype by a milling process is presented. The surface roughness of plan notch ground, measured with a laserprofilometer, shows roughness values lower than 3 μm.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. Brinkhaus J-W (2009) Statische Verfahren zur selbstlernenden Überwachung spanender Bearbeitung in Werkzeugmaschinen. Dr.-Ing, Diss. Leibniz Universität Hannover

  2. Denkena B, Brinkhaus JW, Lange D (2005) Possibilities of sensor transponders in machine tools. In: 10th international scientific conference on production engineering, computer integrated manufacturing and high speed machining

  3. Denkena B, Mohring H-C, Litwinski KM (2008) Design of dynamic multi sensor systems. Prod Eng Res 3:327–331

    Article  Google Scholar 

  4. Düsing JF, Suttmann O, Klug U, Kling R, Litwinski K, Möhring H-C, Denkena B (2010) Neue Ansätze für die Produktionstechnik durch bauteilinhärente Sensorik. Produktion von Leiterplatten und Systemen, Band 12:2887–2892

    Google Scholar 

  5. Griesbach T, Wurz MC, Rissing L (2011) Application of sacrificial layers for the modular micro sensor fabrication on a flexible polymer substrate. Sensor, Nurnberg

    Google Scholar 

  6. Hesselbach J, Hoffmeister H, Schuller B, Loeis K (2010) Development of an active clamping system for noise and vibration reduction. The Int Acad for Prod Eng Anna 59:395–398

    Google Scholar 

  7. Kim GD, Know WT, Chu CN (1999) Indirect cutting force measurement and cutting force regulation using spindle motor current. Int J manuf sci technol 1, 1

  8. Kim T-Y, Woo J, Shin D, Kim J (1999) Indirect cutting force measurement in multi-axis simultaneous NC milling processes. Int J Mach Tools Manuf 39:1717–1731

    Article  Google Scholar 

  9. Leopold J, Clauß D, Klärner M, Poppitz A, Baldoli M, Merlo A, Gimenez M, Larranaga J (2007) Investigations to new fixturing principles for aerospace structures. In: APT 07, international conference on applied production technology, S. 173–S.189

  10. Litwinski KM (2011) Sensorisches Spannsystem zur Überwachung von Zerspanprozessen in der Einzelteilfertigung. Dissertation, Leibniz Universität Hannover, Dr.-Ing

    Google Scholar 

  11. Möhring H-C, Litwinski KM, Gümmer O (2010) Process monitoring with sensory machine tool components. The Int Acad Prod Eng Anna–Manuf Technol 59:383–386

    Google Scholar 

  12. Neuber H (1985) Kerbspannungslehre. Springer, Heidelberg

    MATH  Google Scholar 

  13. Overmeyer L, Dumke M, Heiserich G, Franke S, Schulz L (2010) Power transmission by optical fibers for component inherent communication. J Syst Cybern Inf 8:55–60

    Google Scholar 

  14. Rashid A, Nicolescu CM (2006)) Active vibration control in palletized workholding system for milling. Int J Mach Tools Manuf 46(12/13):S.1626–S.1636

    Google Scholar 

  15. Yao Z, Mei D, Chen Z (2010) Online chatter detection and identification based on wavelet and support vector machine. J Mater Process Technol 210(5):713–719

    Article  Google Scholar 

Download references

Acknowledgments

The authors want to thank the German Research Foundation (DFG) for funding this research within the collaborative research centre 653: Gentelligent Components within their lifecycle.

Author information

Authors and Affiliations

  1. Institute of Production Engineering and Machine Tools, Leibniz Universität Hannover, An der Universität 2, 30823, Garbsen, Germany

    B. Denkena, K. M. Litwinski, D. Brouwer & H. Boujnah

Authors
  1. B. Denkena
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. K. M. Litwinski
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. D. Brouwer
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. H. Boujnah
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to H. Boujnah.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Denkena, B., Litwinski, K.M., Brouwer, D. et al. Design and analysis of a prototypical sensory Z-slide for machine tools. Prod. Eng. Res. Devel. 7, 9–14 (2013). https://doi.org/10.1007/s11740-012-0419-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-012-0419-1

Keywords

Search

Navigation