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Control tool wear

How the wear of a tool is controlled using force measuring sensors.

The control of the wear of a tool or a mechanical organ, takes place through the use of position transducers, which through their expansion measurable even in hundredths of a micron, is able to transform this displacement into a very low voltage (passive currents). Using modules and with the appropriate equipment, by amplifying the signal it is possible, through the programming of a tolerance threshold, to transmit a signal to stop the machine tool or the machinery, either in the event of excessive force caused by wear, or a total lack of force due to tool breakage.

Transducers and sensors are of different types and are chosen according to requirements and the type of control task. They are divided into the families:

Measurement of expansion or compression in microns and transformed into passive currents BDA Kralle. They are usually used for measuring the wear of cutting tools, as the sensor is placed on a tool holder or mechanical arm that expands or compresses during machining. The sensor can also be positioned away from the tool being machined.

DMS- Kralle expansion sensor. Uses the same technology as the BDA Kralle sensor. It differs from the BDA Kralle in that the sensitivity and measurement accuracy is double. This is achieved by a system of strips glued onto the sensor. By screwing the sensor directly onto the tool or a mechanical organ, the deflection takes place through a movement of the strips similar to the bellows of an accordion, where the strips close to each other and open or close depending on the deflection of the component.

PDA piezoelectric expansion sensor. This sensor is suitable for confined spaces and being multidirectional makes it unnecessary to know the exact direction of force. Excellent for measuring torques.

Sound emission hydrophone SEH. Piezoelectric sound measurement transmitted by the sensor through a cooling lubricant jet. The measurement is performed close to the tool or workpiece, with this method we can also check the breakage of drills with a minimum diameter of 0.05mm. The greatest difficulty remains the positioning of the sensor, which must be placed close to the tool.

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