Spike Technical Book

america 106 W Ohio Ave
Mount Vernon, OH 43050
phone (740) 392-1549
fax (740) 392-0230
[email protected]

Technical Book

CONTROL THE FORCE

axial force torque bending moment temperature

spikeamerica.com

measure machining forces
directly on the tool

Measuring force and moments where these occur

axial force drilling / rubbing
torque / threads

bending moment in x- milling
and y-direction

temperature

radio receiver turning

via machine interface

to PC or machine

grinding

Sensory tool holder FSW

14/02/18 2

america

Bending moment – the better alternative for wear detection

bending moment 1 Polar Plot
Y
200 Erhöhung um 100 % vor endgültigem Verschleiß X
150 X

100 1 2

50

0
30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210

L = ca. 10 x r 2
Y
torque
r
10 Erhöhung um 25 % vor endgültigem Verschleiß
14/02/18 8
6
4
2
0
30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210

The bending moment is significantly
more sensitive.

pro-micron TOOL Control 3

What is the polarplot?

neutral

different effects of side forces

offset unbalance

 spike® shows bending moment in polar coordinates
 not in the machine coordinates (workpiece coordinates)

14/02/18 pro-micron TOOL Control 4

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Influences on the polarplot design

Neutral: 1. Step over ae & ap 2. Number of cutting edges 3. Kind of helix

14/02/18 Sensory tool holder SPIKE® 5
6
spike - variants

30-37 mm

interface spike® Clamping system

 CAT CAT 40 I ∅: A ∅:  Collet chuck ER 25
min
CAT 50 30 mm 62,5 mm ER 32
 HSK HSK40 32 mm 62,5 mm
36 mm 62,5 mm ER 40
HSK 50 40 mm 62,5 mm  PowRgrip
46 mm 75,0 mm PG 25
HSK 63 50 mm 75,0 mm  Hydraulic chucks
60 mm 83,0 mm
HSK 100  Grinding arbor
 TC/SK TC 40
 Synchro chuck
TC 50  Weldon-admission
 BT
BT 30

BT 40

14/02/18 pro-micron TOOL Control

america

spike® - target & spike® – solution offer video

video measure machining forces directly on the tool
holder spike ®

Sensory tool holder system

interpretation & spike®kpi configuration & algorythm center

Anwendung Technologie Webinare Ansprechpartner

As a diagnostic tool As a monitoring tool
• Offline process analysis • Online process analysis
• Development of optimization • Monitoring with spike®-KPIs
approaches • Integrity in machine Control
• Mobile use in the spike® suitcase • Online data managment / cloud

examples examples

Overview - application examples

processes benefits + machine connection + strategy

milling cutting edge wear &
breakage detection

drilling unbalance detection borehole quality monitoring
before & during drilling

threading wear measurement chip detection

turning cutting edge wear & 8
breakage detection
14/02/18
pro-micron TOOL Control

spikeamerica.com

Quality control with the kpi

state work piece tool polarplot kpi

new

worn

Cutting
breakage

Polarplot

undamaged 4 cutting edge milling cutter milling cutter with a damaged blade

america

Centrality of the polar plot before and after damage

new tool broken edge new tool broken edge

changes complicated
measurements into easy to

evaluate results

Unbalance detection with spike®

14/02/18 pro-micron TOOL Control 12

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Detection of the displacement of the core bore with the Polar plot

Bending moment Bending moment Bending moment

shifted by approx. 0.05 mm shifted by approx. 0.1 mm shifted by approx. 0.1 mm
14/02/18 Sensory tool holder spike®
13

Take this example in CNC Machining 1.000s of rings per year
189 threads per ring
Threading tool
• 7 flutes
• 13 teeth per flute

0,2 – 0,3 mm wear still ok 0,6 – 0,7 mm wear to be changed

america

Take this thread cutting example 1.000s of rings per year
189 threads per ring
Threading cutter:
• 7 flutes
• 13 teeth per flute

0,2 – 0,3 mm wear 0,6 – 0,7 mm wear

When should the tool be changed ?

video Sensory tool holder spike®

spike® Monitoring

 Tool Wear detection with bending moment  Polarplot for detailed tool charakterization
 Automatic wear measurement with key indicators

Example: After 43 processes Tool OK Example: After 690 processes Warning:Tool Change

Live - view polar - view Live - viLewive - view polar - view

Specific key indicators Specific key indicators
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Rising bending moment Change the tools after 7 rings ?

45 189 2 Max. Biege [Nm] Schwelle 1 Schwelle 2 1.323 8

40 1 34 5 6 7

35

Bending 30
moment
in NM 25

20

15

10

5

0
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 100010501100115012001250130013501400145015001550

Number of threads

But Tools and Material do not behave in a linear pattern

7 rings mean 1.323 threads Less good
good

No of threads

Wear in mm

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Polarplot with bending moment in x and y direction

purple ring wear meassurements

Schneide Verschleiß[mm]
1 0,8
2 0,54
3 0,8
4 0,63
5 0,63
6 0,63
7 0,63

Let the actual forces decide when to change the tool

BM Aera Expon. (BM Aera)

20000.0

18000.0

16000.0

FLÄCHEN-KENNZAHL 14000.0

12000.0

10000.0

8000.0

6000.0

4000.0

2000.0

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
0.0 VERSCHLEIß

Max Wear for resharpening of the tool Max Wear for changing of the tool

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Polarplot

Undamaged 4 fluted mill mill with one damaged flute

Centricity of polar plot before and after damage

New tool Broken flute New tool Broken flute

Turning complicated measurments
into easy to handle trigger values

america

Machine connection

14.02.2018 pro-micron GmbH & Co. KG 23

overview applications optimizing tool lifetime increase productivity

problem solving

milling spike®
drilling
threading sensory tool holder for process diagnosis

overview applications

grinding
lubricants

24

spikeamerica.com

overview applications

problem solving optimizing tool lifetime increase productivity

extend tool tool benefit of material test / Coating
lifetime comparison polarplot machine Small tools
diagnosis
work piece wear
milling positioning evaluation

process Polarplot
optimization

drilling productivity lateral drill secure max. material Clamping
increase hole offset tool comparison
threading grinding
25 exploitation lubricants
14/02/18
process detection of tool 18
analysis core hole comparison
offset

Choose an option

Overview - application examples

milling process- comparison of process diagnosis
optimisation abrasives process
optimisation
turning initiation Polarplot
milling drilling
lubricant comparison of cooling lubricant threading
cooling lubricants pressure analysis
1296
tool analyzer Tool Life Plot Polarplot
software Stacking &
Calculation
14/02/18
Klicken Sie auf ein Feld

america

measurement – milling notch with 6mm end milling cutter

to be minimized peak forces

optimizations:

1. Variation of z-depth:
2. mRielldtferouod3cmnt,i0oso3ttn/cex3hpo,3sf8in.f5e/7e3mds,m7urbam-temat the point of

maximum tool engagement

14/02/18 Result: extend of tool lifetime of more than 50% realized 27

Sensory tool holder spike®

Ex.: Automotive supplier - milling notch with 6mm end milling cutter

SPIKE system viability analysis

spike Sensory tool holder

0,07 € tooling costs in € per component 2% 21%
180 € Machine hour rate 2%
45 min tool change time per workshift 2% 12% 12%
1.500.000 Stk. series volume per year 2%
2H 0%
4.710 € saving tooling costs in series per year 2% 2% 5.000 9% 2% 2% 8V-1 8V-2 4% 6% 5%
3.164 € saving tooling changing costs in series per year 22%% 12% 1.500 20.000 2%
2% 1H-2 3H 5V 7V 12% 0% 9H 1%
7.874 € total savings tool 3H 1H-1 6.000 0% 4.000 3.000 3.000 7.000
0,0 0% 0%
tool number 6.000 2% 0,0 9% 2% 2% 0,0 0,0 4% 11H 12H 13H 14V-1 14V-2
lifetime (number of components) 0% 0,0 50% 0% 0% 0,0 0,0 0% 4.000 7.000 20.000 7.000 50.000
2% 0,0 0,31 0,0 0,0 0,0 0,0 0,0
ratio tooling costs in % 0,0 0,21 0,0 0,0 0,0 21% 6% 2% 5% 1%
optimization of lifetime 0% 0,0 0,52 0,0 0,0 0,0 0% 0% 0% 0% 0%
tooling costs savings in ct/component 0,0 0,0 0,0 0,0 0,0
0,0 0,0 0,0 0,0 0,0 0,0
tooling changing costs savings in ct/component 0,0 0,0 0,0 0,0 0,0
0,0
total savings in ct/component
0,0

Result: 7800€ per year by only one tool

14/02/18 Sensory tool holder spike® 28

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tool qualification by bending moment

bending moment

After 30 milling sessions: After 120 milling sessions After 180 milling sessions
cutter 1: 44,8 Nm cutter 1: 56,2 Nm
cutter 2: 45,8 Nm cutter 2: 55,5 Nm cutter 1: 56,6 Nm
cutter 3: 44,1 Nm cutter 3: 60,9 Nm cutter 2: 55,9 Nm
cutter 3: 79,1 Nm
time

cutter 1 shows best price-performance ratio because it‘s cheaper than cutter 2 & cutter 3

14/02/18 Sensory tool holder spike® 29

comparing changes of forces

Carbide milling tool bending moment
coating: TiAlN
cooling: external 200 tool worn
z: 4 150
d (mm): 12
n (U/min): 2785 Increase of 100% before
vf (mm/min): 557 100 final wear
ae (mm): 6
ap (mm): 5 50
material: DIMO 2311
0
30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210

torque

10 tool worn
8

6 Increase of 25% before
4 final wear

2

0
30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210

14/02/18 Sensory tool holder spike® 30

america

productivity increase – doubling of feed useful?

Axial force: vf = 3,0 m/min Potential for savings
recognizable:

vf = 1,0 vf = 1,5 m/min  Doubling of feed means only
m/min finish drilling increase of 30% in axial force
pre drilling
time saving  Time saving:
0,25 sec / drill

14/02/18 Sensory tool holder spike® 31

productivity increase – pre drilling useful?

with pre without pre
drilling drilling

Axial force:

without pre
drilling

with pre result:
drilling
time saving  time saving:

0,76 sec / drill

 polar plot shows a circle

 hole is not exactly centric
anymore

 pre drilling should not be
dropped completely

14/02/18 Sensory tool holder spike® 32

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productivity increase – shortening the pre drilling useful?

Axial force increased with pre shortened pre
shortened pre feed drilling drilling
drilling
bending moment bending moment

original time saving result:
process  polar plot shows no abnormality

 pre drilling can be shortened

14/02/18 time saving: 0,25 sec + 0,22 sec = 0,47 sec (23 % process time) 33
Sensory tool holder spike®

e.g.: drilling Ø 11mm correlation of diameter of circle and offset

bending moment bending moment bending moment

circle Ø: ca. 2 Nm circle Ø: ca. 5 Nm circle Ø: ca. 9 Nm
offset: 0,06 offset: 0,109 mm offset: 0,327 mm

0.40 77 mm result:
0.30 the diameter of the circle in the polar plot
offset (mm)0.20 is an indicator for the lateral offset of the
0.10 drilled hole.
0.00 2 Diam4eter of d6rilling (N8m) 10

0

14/02/18 Sensory tool holder spike® 34

america

benefit of polar plot

torque bending moment Milling with 3 asymmetric flutes

higher low forces
forces

detail

 Unfiltered stored raw data allows detailed analysis flute doesn‘t cut
of segments

 polar plot enables very quick visualisation of
possible process problems

14/02/18 Sensory tool holder spike® 35

material test / machine diagnosis bending
moment
bending moment

radial milling 5th Process

4th Process

3rd Process

2nd
Process
1st Process

result:

 Support of calculation of tool life time of unknown materials with direct wear measurement

 „dent“ in force deflection is an indicator for loose steering mechanism
information afterwards: spindle bearing defective! – has been replaced

14/02/18 Sensory tool holder spike® 36

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detection of core hole offset

Analysis of signal change while non centric core hole drilling

bending moment torque thread M8:

orange: Offset ca. 0,3 mm
green: Offset ca. 0,1 mm

bending moment shows core hole offset torque shows no change

14/02/18 Sensory tool holder spike® 37

detection of core hole offset with polar plot

bending moment bending moment bending moment

offset ca. 0,05 mm offset ca. 0,1 mm offset ca. 0,3 mm

14/02/18 Sensory tool holder spike® 38
america

secure maximum tool exploitation – tool comparison

Axial force: new drill
after 2000
cutting edges of new
pieces driller

work piece 1 work piece 2 result:

 There is absolutely no

rising of axial force
detectable

 Driller is obviously

replaced too early

 Much longer tool

exploitation possible

14/02/18 Sensory tool holder spike® 39

secure maximum tool exploitation – tool comparison

Axial force: new drill result:

resharpened  obviously different cutting force
drill
characteristics

 resharpened drill has not the

same dimensions as the original

drill

 different tool life time is possible

work piece 1 work piece 2 new drill resharpened drill

14/02/18 Sensory tool holder spike® 40

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process analysis – measurement of 9 threading operations thread M6:

torque bending moment

There are visible additional peaks in two threads

14/02/18 Sensory tool holder spike® 41

process analysis – three different point of views

Axial force result:
torque
 In both threads a chip was still inside
after operation

 Bending moment detects chip clearly
through an additional peak

 Chip cannot be detected with torque or
axial force signal

bending moment chip

14/02/18 Sensory tool holder spike® 42
america

comparison of cooling lubricants test fluid 2
High different loads test fluid 3
torque test fluid 1

e.g.:
thread tapping

14/02/18 Different cutting forces of cooling lubricants in torsion measurement visible 43

Sensory tool holder spike®

wear evaluation by bending moment
process: carbide milling cutter (Ø 10mm), material
42CrMo4
vf = 446 ae = 2

n = 3380 ap = 3 milling torque
travel
bending moment

74 m

47 m

305,8m
m

Increase of bending moment of 30% at a force-noise-ratio of torque is significantly less.
measured wear of 0,13 mm.

14/02/18 Sensory tool holder spike® 44

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wear evaluation by bending moment
change the resultant force vector by specific
polar plot at 0,8m, 35m, 74m wear

wear: 0,8m 35m 74m

Different wear each cutting force distribution at flute changes by material
recognizable welding.

14/02/18 Sensory tool holder spike® 45

work piece positioning

Pos. 1 Pos. 2 bending moment
torsion
Spindle Pos. 4
Spindle Pos. 3
Spindle Pos. 2
Spindle Pos. 1

Spindle L
Spindle R

14/02/18 Sensory tool holder spike® 46
america

cutting parameters optimizationbending moment Increase in depth has virtually no effect on
(Nm) the forces
1) 1)
Increasing the feed rate between the radius
2) machining :
 Indicates no increase of force
timestamp error  leads to time savings of 10 seconds
(hh:mm:ss) 2)
process time (14% time saving)
bending moment increased  peak indicates programming error
(Nm) feed
Summary:

 simple comparison of different clamping
situations / machines possible

 direct information on process
improvement potentials

 easy detection of program errors

timestamp originally
(hh:mm:ss)
Sensory tool holder spike®
14/02/18 47

drill test in CFK material: CFRP 5mm Overview of forces: tool 1 n=436
Comparison axial force: tool1 and vf = 305 mm/min
front back
2 Axial force
Result: torque
 Visualisation of forces even with
tools1m: abllul edrgirllaspphossible bending moment
 Possibility to establish a
polar plot
relationship between pictures
and graphs / polar plot

tool 2: orange Sensory tool holder spike® 48
graph
spikeamerica.com
14/02/18

drill test in Graphite

3 mm drill finish drilling
NEW
3 mm drill center drilling
damaged
Comparison: Axial force of both drills N = 2500 vf = 150 mm/min
14/02/18
Sensory tool holder spike® 49

process analysis – tool comparison

torque: Thread
ThreMad 44 :

Thread 3

Thread 2

Thread 1

selection of threading tool:
The comparison of different versions of M4 threads shows
significant level deviations in torque.

14/02/18 Sensory tool holder spike® 50

america

process optimization Vc= 25 m/sec results:
Vc= 20 m/sec  Significantly differing forces by
torque Vc= 18 m/sec
varying vc
torque Vf 160 mm/min  At vc 18–20m/sec significant
Vf 130 mm/min
force variation
possible reason: process may be
not stable
 With higher vc the force increases
during the grinding process of
one notch
 For lower vf the process is stable
since the forces are always equal

14/02/18 Sensory tool holder spike® 51

e.g.: polar plot while grinding

polar plot: specific characteristic is changing by varying vc

asymmetric bending moment

bending moment bending moment

more flat vc = 20 m/sec vc = 25 m/sec

vc = 18 m/sec Sensory tool holder spike® 52

14/02/18

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process diagnosis – grinding of a deep hole drill
Axial force

bending torque Polar plot shows, that forces
moment temperature along the circle of the
grinding wheel are not equal!
 unbalanced?
 vibrations inside the

system?

bending moment

14/02/18 Detail analysis shows a machine related 53
frequency in bending moment and axial
force

Sensory tool holder spike®

directly comparing grinding wheels of 2 manufacturers

grinding
wheel 1

grinding
wheel 1

grinding
wheel 2

bending moment: grinding
wheel 2
Significant deviations detectable: notch grinding:
 Clearly higher bending moments (=push awa of the Vc = 25 m/sec 54
Vf = 160 mm/min
wheel) and torque (= cutting force) of grinding wheel
1
 Wheel 2 shows a consistent level of cutting force
over the whole process

14/02/18 Sensory tool holder spike®

america

deep hole drilling

Axial force

Cooling lubricant force signal
pressure

Process analysis / machine monitoring:

Pressure changes at the tool holder are measurable with inner cooling through axial

force

14/02/18 Sensory tool holder spike® 55

variation of inner cooling pressure

Axial force: 50 bar 60 bar
+380 N +390 N
20 bar
695 N 30 bar 40 bar Process analysis /
+350 N +380 N machine monitoring:

Linear correlation
between pressure and
axial force

14/02/18 Sensory tool holder spike® 56

spikeamerica.com

Approach of process optimization

1. Increase of feedrate 0,8  1  2 m/min
2. Reduction of the torsion by 40% by doubling the speed from 6000 rpm to 12,000 rpm

at 2 m/min

10 Nm process data:
time: 16 sec, 12 sec, 6 sec
Torsion
Nmmax: 4,5 Nm, 6 Nm, 10,5 Nm

6 Nm results:
• Reduction of process time by 62% with
same torsion
• Identification of potentials of further
optimization

14/02/18 Sensory tool holder spike® 57

Polarplot helps to develop tools

Profile of the tool
with ae = 2 mm, ap = 6 mm

• Visualization of cutting edges and helix
• 2 ° different angle of helix rise leads to

differences in force values

14/02/18 Sensory tool holder spike® 58
america

Polarplot helps to develop tools

Torsion & bending moment when changing the cutting angle

Torsion 12 Nm bending moment

Cutting angle 8°
Cutting angle 16°
Cutting angle 20°
Cutting angle 24°

0 Nm

Polarplot stacking

14/02/18 Sensory tool holder spike® 59

TAS 2016 – Tool Life Plot visualization single graph
folder of data
Graph comparison

Select data files
Select signal and

method

report & calculation

14/02/18 Sensory tool holder spike® 60

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TAS 2016 – Graphic Polarplot Calculation

Automatic
scale

list of files

14/02/18 Sensory tool holder spike® report & calculation

TAS 2016 – Polar Plot Stacking 61

14/02/18 Sensory tool holder spike® List of Polarplot files
america select files

value
calculation
angle calculation

62

Force and torque measurement directly at the point of action

sensory tool holder Axial force

Y Torsion
X Bending moment in x and y

direction Analysis software Tool Analyser - optional

Temperature

radio receiver via USB to PC

visualization software Tool Measurement

Turning spike® - functionality

The special feature of our torsion holder spike® is that the calculated
cutting force Fc can also be displayed with it!

=


r

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Turning spike®-process optimisation

A "42CrMo4" round steel bar Ø 68 was turned lengthwise with 5 different feed values. The infeed remains

constant for all examples (ap = 2 mm). 50% 100% 150% 200%

Vorschub „f“

mm/U f = 0,1 f = 0,15 f = 0,2 f = 0,25 f = 0,3

Mmax(Nm) 2030 2590 3120 3650 4150

27,6% 53,7% 79,8% 104,4%

Turning spike®-process optimisation

A "42CrMo4" round steel bar Ø 68 was turned lengthwise with 3 different infeeds. The feed rate remains

constant for all examples (fU = 0.2 mm/rev). 100% 200%

Zustellung „ap“

(mm) ap = 1 ap = 2 ap = 3

Mmax (Nm) 1650 3110 4500

88,5% 172,7%

america

Turning spike®-process optimisation

Three different materials „ Inconel718 / 42CrMo4 / Ti6424“were turned lengthwise with the same feed and feed
values (ap = 2 mm / f = 0.1 mm/rev).

When comparing the bending moment,
the vibrations that occur during the
machining process of the "Inconel718"
can be seen!

bending moment

Mmax: 2500 Nm / 2030 Nm / 1360 Nm

Turning spike®-process optimisation

Three different materials „ Inconel718 / 42CrMo4 / Ti6424“were turned lengthwise with the same feed and feed
values (ap = 2 mm / f = 0.1 mm/rev).

Fz= Fz=

Fmax: 490 N / 295 N / 270 N When comparing the tensile compression force, the
force at the end of each machining process can be
seen when exiting the material. (angle of incidence!)

spikeamerica.com

Optimization of coating

Analysis of bendingmoment Teil 1

Analyse Ana
lyse
Tool Life Graph
Anal
Beschichtung „grau“ yse
Beschichtung „gold“
Beschichtung „schwarz“ 75

Teil 400 Schicht „gold“
Schichtung „schwarz“
Schichtung „grau“

material: 20MnCr5 pro-micron TOOL Control
source:
14/02/18

Detecting clamping performance

18mm

14/02/18 pro-micron TOOL Control 76
america

Detecting clamping performance
Detecting clamping performance – moving tool

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Detecting clamping performance – moving tool

500 Nm

14.02.2018 4400 N 79

Same process only with Filter of 1

pro-micron GmbH & Co. KG

Detection clamping performance – vibrations

Same process only with Filter of 1

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