Acceleration-based spindle monitoring based on geometric error motions

Published

April 3, 2025

Author(s)

Aaron Cornelius, Gregory Vogl, Ryan Hall, Yongzhi Qu

Abstract

The development of intelligent machine tools requires integrating sensors that allow the machine to monitor, diagnose, and control the machining process. However, existing sensors for monitoring tool vibrations are intrusive and difficult to integrate in a production machining system. This paper describes how spindle-mounted accelerometers can be used to model spindle-speed dependent error motions in situ. It extends on previous work by applying a geometric model for interpreting tool holder displacements and spindle error motions from the motion of a laser that is coaxially mounted in a tool holder, providing an accurate and interpretable basis for training models that output geometric error motions via acceleration inputs. Trained data-driven models shows the potential for use of spindle-mounted accelerometers to accurately estimate geometric error motions, even during spindle rotation with radial loads.

Proceedings Title

20th CIRP Conference on Modeling of Machining Operations

Volume

133

Conference Dates

May 21-23, 2025

Conference Location

Mons, BE

Conference Title

CIRP Conference on Modelling of Machining Operations

Pub Type

Conferences

Download Paper

https://doi.org/10.1016/j.procir.2025.02.095

Local Download

Keywords

Machine tool, Modeling, Monitoring

Citation

Cornelius, A. , Vogl, G. , Hall, R. and Qu, Y. (2025), Acceleration-based spindle monitoring based on geometric error motions, 20th CIRP Conference on Modeling of Machining Operations, Mons, BE, [online], https://doi.org/10.1016/j.procir.2025.02.095, https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=958993 (Accessed October 17, 2025)