Force Response Mapping
The Concept
Machining Force Response Mapping (MRMF) refers to the process of measuring and providing information about the forces acting on a tool during the machining process. This can be done through various methods, such as sensors on the tool or machine, or through calculations based on the cutting parameters and material properties. The force feedback can be used to optimize the machining process, improve the surface finish and dimensional accuracy of the machined part, and extend the life of the tool. It can also be used for real-time monitoring of the machining process to detect any deviations from the desired cutting conditions and take corrective action if necessary.
Its Effects
There are several potential economic benefits of using MFRM in manufacturing operations. Overall, the use of MFRM can lead to increased safety, competitiveness, sustainabilty and cost savings, for manufacturing operations.
Some of the potential benefits include:
Uphold Safety Standards
By detecting changes in the material properties of aircraft components, which may indicate the presence of defects or other deleterious mechanisms. Early detection leads to corrective action to ensure that the final product meets all necessary safety standards.
Improved Efficiency
By measuring the forces acting on the tool during machining, it is possible to optimize the machining process and improve the efficiency of the manufacturing operation. This can result in reduced cycle times, higher production rates, and lower energy consumption.
Enhanced Quality
MFRM can be used to improve the surface finish and dimensional accuracy of the machined parts, resulting in higher quality products that are more likely to meet customer requirements.
Enhanced Production Safety
MFRM can be used to detect abnormal cutting conditions that may indicate a problem with the tool, machine or material. This can help to prevent accidents and improve the safety of the manufactured component and cutting operation.
Improved Sustainability
By minimising energy usage and reduce the amount of waste material generated. Sub-standard material can also be identified earlier, and upcycled to other industries. This can help to lower the carbon footprint of the manufacturing operation and contribute to more sustainable manufacturing practices.
Reduced Toolwear
By monitoring the forces acting on the tool, it is possible to adjust the cutting parameters to reduce tool wear and extend the life of the tool. This can result in lower tooling costs and reduced downtime for tool changes.
The Method
STAR group researchers have developed an integrated suite of sensors and electronics that allows high-frequency capture of a wide range of forces—coupled with a flexible software package built from the ground up to allow for fast setup, multi-channel measurement and ease-of-use.
Our latest developments have taken Force Response Mapping to the next level and moved it closer to industrial use, allowing the deployment of this technology in industrially relevant environments and machines.
Publications of Interest
Rapid acquisition of digital fingerprints of Ti-6Al-4V macrotexture from machining force-feedback measurement data.pdfSuarezetalFatigue2021.pdfTitanium_Alloy_Microstructure_fingerprint_Plots-From-In-process_Machining.pdfDigital Fingerprints of microstructural vairation in titanium alloy hip joint forgings.pdf