The field of mechanical manufacturing is becoming more and more demanding on machining accuracy. It is essential to monitor and compensate the deformation of structural parts of a heavy-duty machine tool. The deformation of the base of a heavy-duty machine tool is an important factor that affects machining accuracy. The base is statically indeterminate and complex in load. It is difficult to reconstruct deformation by traditional methods. A reconstruction algorithm for determining bending deformation of the base of a heavy-duty machine tool using inverse Finite Element Method (iFEM) is presented. The base is equivalent to a multi-span beam which is divided into beam elements with support points as nodes. The deflection polynomial order of each element is analysed. According to the boundary conditions, the deformation compatibility conditions and the strain data measured by Fiber Bragg Grating (FBG), the deflection polynomial coefficients of a beam element are determined. Using the coordinate transformation, the deflection equation of the base is obtained. Both numerical verification and experiment were carried out. The deflection obtained by the reconstruction algorithm using iFEM and the actual deflection measured by laser displacement sensors were compared. The accuracy of the reconstruction algorithm is verified.
Real-time monitoring of deformation of large structure parts is of great significance and the deformation of such structure parts is often accompanied with the change of curvature. The curvature can be obtained by measuring changes of strain, surface curve and modal displacement of the structure. However, many factors are faced with difficulty in measurement and low sensitivity at a small deformation level. In order to measure curvature in an effective way, a novel fibre Bragg grating (FBG) curvature sensor is proposed, which aims at removing the deficiencies of traditional methods in low precision and narrow adjusting. The sensor combines two FBGs with a specific structure of stainless steel elastomer. The elastomer can transfer the strain of the structure part to the FBG and then the FBG measures the strain to obtain the curvature. The performed simulation and experiment show that the sensor can effectively amplify the strain to the FBG through the unique structure of the elastomer, and the accuracy of the sensor used in the experiment is increased by 14% compared with that of the FBG used for direct measurement.