Calibration and Implementation of a Torque and Temperature Sensor- Integrated Tooling

A transmitter system has been developed to collect high bandwidth data from torque and temperature sensor integrated cutting tools. The system is useful for collecting high resolution end milling torque and tool temperature during cutting without interfering with the cutting process. To achieve this, a Bluetooth transmitter and data conditioning sys-tem has been designed and integrated into an end milling tool holder. The wireless unit transmits a signal from a dual sensor-amplifier system. The system is designed to power and sample a variety of dynamic sensors including accelerometers, strain gages, and thermocouples. The tool holder can simultaneously sample two sensors from a sensor integrated end milling tool. These sensors reside inside of the endmill tooling and inter-face via an electrical connector within the tool holder. The compliance of the tool and tool holder are unaffected by the sensing system. A tool integrated with a torque sensor and thermocouple is demonstrated. The system is calibrated and cutting torque and tool temperature signals are observed.