Tool Deflection Control by a Sensory Spindle Slide for Milling Machine Tools

A conventional spindle slide of a milling center is enhanced to a force “feeling” component for process monitoring and control tasks. The feeling ability is realized by integrating strain gauges in notches machined into the structure. This force sensing allows the identification of the static tool stiffness and enables the online detection of the tool deflection during milling processes. Based on a communication via PROFIBUS between the monitoring system and the machine control, the tool deflection is controlled online in the milling center by adjusting the axis feed. The approach shows considerable improvement regarding surface accuracies.