Feeling machines for online detection and compensation of tool deflection in milling

In milling, the tool deflection negatively affects the accuracy of the workpiece geometry. Feeling machineswith force sensing capabilities represent a promising enabler to detect and to compensate the deflectionrelated machining failures in real time. This paper gives an overview about current applications of feeling machine tools and developments of monitoring and compensation systems for tool deflection. At first, a method to integrate strain sensors within rigid machine tool structures is introduced. Secondly, the prototypical application within commercial milling centres is presented. Finally, two compensation strategies for tool deflection via feed- and position-based control are discussed and experimentally evaluated.