Fiber Bragg Grating Sensors for Dynamic Machining Applications

Fiber Bragg grating sensors have attracted considerable attention for measurement applications due to their greatly reduced size, low weight, and immunity to electromagnetic interference in comparison with traditional sensing methods. Dynamic measurement of industrial machine tools is useful for gauging surface accuracy, monitoring tool condition, and predicting process stability, but requires a robust sensing scheme. The small size and high natural frequencies of micro machining tools coupled with a harsh manufacturing environment can render traditional sensors ineffective. This work presents a new method for measuring tool motion with fiber Bragg grating strain sensors. The feasibility of the sensing scheme is first demonstrated with a simple bench-top cantilever beam experiment. Then, a method for potting the sensors in the through coolant holes of a 1/8″ carbide end mill with a high-viscosity gap-filling cyanoacrylate is demonstrated. Comparative structural analysis tests demonstrate the effectiveness of the sensors. Measurements of tool motion during cutting are presented. Finally, methods of noise reduction and improving signal accuracy are discussed.