An Integrated Force Sensor Solution for Process Monitoring of Drilling Operations

Two piezo electric force sensor rings were developed and integrated into a direct driven motor spindle for online process monitoring of machining processes. Experimental results are presented which demonstrate the performance of the integrated force sensor during drilling operations. Performance comparisons are made between the integrated force sensors and traditional monitoring sensors such as motor power and acoustic emission. The non cutting influences such as spindle dynamic loading contained in the integrated sensor signals are identified. The potential application of the integrated force sensors for process monitoring encompassing tool condition monitoring, spindle condition monitoring and collision detection is demonstrated.