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

"This Small Business Innovation Research Phase I project describes an innovative approach for measuring vibration during the machining process as well as during characterization of advanced machine tools. We believe that our approach using a fluid jet as a probe will lead to an accurate, robust and low cost sensor. Driven by higher productivity, throughput and quality goals, the machining industry has an increasing need for improved characterization of machine tools 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, advanced machine 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 for monitoring during the milling process, and (4) be compact and low cost. To date, there is no sensor commerciallyavailable that can fulfill these requirements. The development of an accurate, robust and low cost sensor to measure tool vibrations for both characterization and monitoring will be of great value. Our active fluid probe, as part of a machine control system, has the potential to reduce machine tool vibrations, thereby improving surface finish and increasing throughput. The