Real-time measuring method to measure the micro-displacement of a rotating cutter in precise piston noncylinder pinhole boring

This paper presents a novel real-time measuring method to measure the micro-displacement of a rotating cutter in precise piston noncylinder pinhole boring. A noncontact and interference-free approach is used to dynamically collect data on the cutter’s displacement by using two perpendicular electric eddy sensors. Data from the sensors are processed by using the corresponding algorithm according to the position of the boring cutter. The mathematical model is established, and the error is separated by using the error separation technique and then compensated. A typical application of the method in the smart boring bar with the embedded giant magnetostrictive actuator is demonstrated. Several experiments are carried out, and the results indicate that the real-time measuring method can measure the micro-displacement of a rotating boring cutter effectively.