Estimation of the virtual workpiece quality by the use of a spindle-integrated process force measurement

Existing workpiece quality estimations utilize material removal simulations in combination with dynamic force measurements. The common force measurement method, using plate dynamometer, is not practicable due to space-constrains, high costs and inertial forces in case of 5-axis machining that falsify the measurement considerably. This paper examines the potential of workpiece quality monitoring by the use of a spindle-integrated high-resolution force measurement that uses displacement sensors. Considering the experimentally determined transfer-function between the force at the TCP and the displacement sensor, it is possible to calculate cutting forces during machining. The virtual quality is compared with CMM measurements.