Abstract: A system and method are provided for real-time measurement of tool forces. A relationship between a sensor characteristic and tool forces is determined by directly measuring tool forces for a standard tool, work piece, and part program. The sensor characteristic for a CNC machine at the user facility is then measured for the standard tool, work piece, and part program, providing a relationship between the sensor characteristic at the user facility and tool forces. If the sensor is not conveniently attached to the work piece or the part program is not sufficiently robust in cutting conditions, the work piece and part program are replaced by a sacrificial work piece and sacrificial part program. The sacrificial work piece and sacrificial part program are selected to accommodate the sensors and to provide sufficient robustness in cutting conditions to accurately determine the process model parameters for the sacrificial work piece.

Abstract: A system and method are provided for real-time measurement of tool forces. A relationship between a motor characteristic and tool forces is determined by first directly measuring tool forces for a standard tool, work piece, and part program in a central facility. A force profile indicative of the tool forces and the standard tool, work piece, and part program are provided to a user at a user facility. The motor characteristic for a CNC machine at the user facility is then measured for the standard tool, work piece, and part program. Based on the force profile determined at the central facility, the relationship between the motor characteristic and tool forces is determined. Thereafter, the motor characteristic of the CNC machine is measured for a desired tool, work piece, and part program and converted to tool forces using the relationship between the motor characteristic and tool forces.

Abstract: The present invention provides a device for determining the dynamics of a tool sited in a CNC machine, as encapsulated by the Frequency Response Function. The device uses an actively controlled electromagnet to excite forces on the tool. The force is excited in a non-contact manner, allowing the force to be applied to both a stationary and a rotating tool. The displacement is measured by standard means, such as accelerometers, optical displacement or capacitance sensors. The ratio of the force and the displacement in the frequency domain is the Frequency Response Function. The force may be applied as a pure sine wave, providing the Frequency Response Function at the frequency of the sine wave. Varying the frequency of the sine wave provides the Frequency Response Function over the range of frequencies of interest. The control of the force profile is handled entirely by the automated controls and requires no special skills, training or manual interaction by the user.

Abstract: The present invention provides a device for determining the dynamics of a tool sited in a CNC machine, as encapsulated by the Frequency Response Function. The device uses an actively controlled electromagnet to excite forces on the tool. The force is excited in a non-contact manner, allowing the force to be applied to both a stationary and a rotating tool. The displacement is measured by standard means, such as accelerometers, optical displacement or capacitance sensors. The ratio of the force and the displacement in the frequency domain is the Frequency Response Function. The force may be applied as a pure sine wave, providing the Frequency Response Function at the frequency of the sine wave. Varying the frequency of the sine wave provides the Frequency Response Function over the range of frequencies of interest. The control of the force profile is handled entirely by the automated controls and requires no special skills, training or manual interaction by the user.