Accurate measurement of micromachining forces through dynamic compensation of dynamometers

In this paper, we present a comprehensive approach for accurate measurement of high-bandwidth three-dimensional (3D) micromachining forces through dynamic compensation of dynamometers. Accurate measurement of micromachining forces is paramount to gaining fundamental understanding on process mechanics and dynamics of micromachining. Multi-axis dynamometers are used to measure 3D machining forces. However, specified bandwidth of these devices is below the frequencies arising during micromachining while using ultra-high-speed (UHS) spindles. This limitation arises from the effects of the dynamometer's structural dynamics on the measured forces. Therefore, accurate measurement of micromachining forces entails high frequency correction of the signals acquired by the dynamometer by removing the influence of those effects. The presented approach involves: (1) accurate identification of 3D force measurement characteristics of the dynamometer within a 25 kHz bandwidth to capture the effects of the dynamometer dynamics; (2) design of a pseudo-inverse filter-based compensation technique to remove the influence of the dynamic response in 3D; and (3) validation of the compensation technique through custom-devised experiments. Subsequently, the compensation method is applied to the micromilling process to obtain accurate broadband 3D micromachining forces using a miniature multi-axis dynamometer. It is concluded that the presented approach enables accurate determination of 3D micromachining forces. The presented compensation technique is also readily applicable for expanding the bandwidth of large dynamometers.