A smart milling tool bar using piezoelectric layers to combine force measurement and vibration reduction

Deep cavity parts which are the key parts of aero engine need strict requirements for hardness, strength and surface processing quality in the production process. However,due to its complex dynamic characteristics during machining and the use of large aspect ratio tools, it is prone to problems such as tool chatter, tool wear, and high cutting temperature in the milling process. Therefore, based on the piezoelectric effect, an intelligent vibration reduction tool for cutting force online measurement and tool vibration control is proposed. The equivalent mechanical model of the sensor and the principle model of the vibration reduction milling tool are established. On this basis, the accuracy of the force measuring system and the feasibility of the damping tool are verified by static calibration experiment with gradually increasing weights in each direction to compare actual and measured value. The experimental results show that the measurement error between the piezoelectric dynamometer and the bench dynamometer is less than 8%. With the increase of the driving voltage, the damping effect of the damping device is gradually improved. Compared with before damping, the tool tip displacement is reduced by 46.2%, and the surface roughness of the workpiece in the stable cutting stage is reduced from 2.143 μm to 1.442 μm, which is reduced by 32.7%.