Active Ultrasonic Fluid Probe for Vibration Monitoring of High Speed Machine Tools

This Small Business Innovation Research Phase II project describes an innovative approach for measuring vibration during the machining process as well as during characterization of advanced machine tools. This sensor uses ultrasonic waves guided in a fluidjet to measure the vibration of the cutting tool. This approach is highly sensitive, robust and low cost. Driven by higher productivity, throughput and quality goals, the machining industry has an increasing need for improved characterization of machinetools and for controlling vibration and chatter during the machining process. There is a growing demand for high-speed milling as well as an increasing use of small size tools and of difficult to machined advanced materials. To reach these goals, advancedmachine system must rely on accurate sensors to measure and to control vibrations. The sensor should: (1) accurately measure vibrations, (2) be insensitive to the machining environment, (3) be used both for characterization prior operation and formonitoring during the milling process, and (4) be compact and low cost. To date, there is no sensor commercially available that can fulfill these requirements. The development of an accurate, robust and low cost sensor to measure tool vibrations for bothcharacterization and monitoring will be of great value.