Kistler presents solutions for tool monitoring and data analysis

At EMO Hannover, Kistler will present its solutions for cutting force measurement in development and production. While its rotating cutting force dynamometer (RCD) with a piezoelectric sensor simplifies R&D activities, the Piezo Tool System in combination with the maXYmos process monitoring system ensures optimised, transparent machining processes.

The reliable monitoring of machining processes provides valuable real-time data on the current process, thus establishing the basis for predictable, productive and reproducible manufacturing processes. During micromachining or finishing processes in particular, tool monitoring was practically impossible up to now due to the small forces.

The Piezo Tool System (PTS) from Kistler, which was developed in cooperation with Paul Horn, measures cutting force during turning with highly sensitive sensors located close to the shaft, thus establishing a reliable basis for optimisation of these challenging processes.

The PTS integrates high-precision sensor technology into high-quality toolholders and tools and can be customised to be compatible with a variety of machine types and interfaces without altering the characteristics of a traditional machining system. Continuous cutting force measurement allows for optimised utilisation of the tool lifespan while at the same time reducing the effort required on the part of the machine operator.

Anomalies in the material and cutting tool wear or even tool breakage are detected immediately, thus preventing rejects and maximising machine utilisation times.

In combination with a process monitoring system from the maXYmos series from Kistler – which will also be presented at EMO Hannover – all measurement data can be efficiently recorded and visualised and used to optimise and automate production processes.

Gunnar Keitzel, head of the business centre for manufacturing technologies at Kistler, says: “With the combination of PTS tools and the maXYmos process monitoring system, and thanks to our cooperation with HORN, we are able to offer a complete solution that is able to make highly sensitive measurements and can be integrated into any production systems due to its interfaces.”

Highly dynamic measurements

The wireless rotating cutting force dynamometer (RCD) from Kistler simplifies cutting force measurement for research and development, but can also be used in industrial production processes such as milling, drilling, grinding and superfinishing. The measured values for the forces Fx, Fy and Fz and the torque Mz are transmitted via a wireless low-energy connection with a range of up to five metres.

Thanks to its wide measuring range of up to 20 kN as well as its high resolution and sensitivity, the wireless RCD from Kistler can be used for a variety of different processing steps from roughing all the way to finishing. The integrated piezoelectric measurement technology with a sampling frequency of 10 kHz is perfect for recording data from highly dynamic processes of up to 16,000 rpm that would take other technologies to their limits.

Ideally, the wireless RCD is used together with the new PTS app from Kistler. This software automatically records, analyses, and visualises data from machining processes, creates trend analyses, and also includes an option to communicate with the machine. Consequently, data evaluation and storage with the PTS app makes it possible to automate large-scale testing series for research and development at a higher level and to significantly increase efficiency.

Kistler also offers a number of specialised services for cutting force applications – from calibration of dynamometers right through to optimisation of milling processes.