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  4. Tool-holder integrated printed piezoceramic sensors for process state classification and tool-wear progress evaluation in turning
 
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2025
Journal Article
Title

Tool-holder integrated printed piezoceramic sensors for process state classification and tool-wear progress evaluation in turning

Abstract
Tool condition monitoring strategies in turning processes, using multiple sensor sources to measure dynamic quantities (e.g., force, acoustic emissions, acceleration), has gained significant attention in conjunction with machine learning methods. As a novel approach, the introduction of printed piezoceramic thick films in machine tools allows the customization of sensor shape and placement, optimized to fit the tool holder’s geometry and process boundary conditions. This work proposes integration concepts using two configurations of printed piezoceramic sensors. This includes the use of a finite element simulation to estimate the generated electric charge from sensors on three locations on the tool holder, induced by transient mechanical loading. The design is validated under controlled mechanical loading and tested across various cutting conditions and tool-wear states. Signal information content from each sensor location, relative to different machining conditions, is assessed through recursive feature elimination and validated using dimensionality reduction. Finally, tool-wear progress is evaluated using the selected features.
Author(s)
Panesso Perez, Miguel Antonio  
Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU  
Berthold, Jan
Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU  
Hamm, Lucas  
Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU  
Li, Zongshuo
RWTH Aachen  
Drossel, Welf-Guntram  
Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU  
Bergs, Thomas
RWTH Aachen  
Journal
Procedia CIRP  
Conference
Conference on Modeling of Machining Operations 2025  
Open Access
DOI
10.1016/j.procir.2025.02.066
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Language
English
Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU  
Keyword(s)
  • printed piezoceramic thick films

  • turning

  • dynamic cutting forces

  • recursive feature elimination

  • random forest classifier

  • dimensionality reduction

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