A High Performance Sensor for Triaxial Cutting Force Measurement in Turning

Abstract

This paper presents a high performance triaxial cutting force sensor with excellent accuracy, favorable natural frequency and acceptable cross-interference for high speed turning process. Octagonal ring is selected as sensitive element of the designed sensor, which is drawn inspiration from ring theory. A novel structure of two mutual-perpendicular octagonal rings is proposed and three Wheatstone full bridge circuits are specially organized in order to obtain triaxial cutting force components and restrain cross-interference. Firstly, the newly developed sensor is tested in static calibration; test results indicate that the sensor possesses outstanding accuracy in the range of 0.38%–0.83%. Secondly, impacting modal tests are conducted to identify the natural frequencies of the sensor in triaxial directions (i.e., 1147 Hz, 1122 Hz and 2035 Hz), which implies that the devised sensor can be used for cutting force measurement in a high speed lathe when the spindle speed does not exceed 17,205 rev/min in continuous cutting condition. Finally, an application of the sensor in turning process is operated to show its performance for real-time cutting force measurement; the measured cutting forces demonstrate a good accordance with the variation of cutting parameters. Thus, the developed sensor possesses perfect properties and it gains great potential for real-time cutting force measurement in turning.

The Development of a Triaxial Cutting Force Sensor Based on a MEMS Strain Gauge

“…Its accuracy is calculated as 3.64%, 1.36%, and 13.82% in triaxial directions. Specifically, its sensitivity is about 27–30 times that of our previous developed metal strain gauge sensor as reported in [ 21 ], and it is also higher than that of sensors introduced in the literature [ 14 , 15 ], which proves that using a MEMS strain gauge is a workable method of improving a sensor’s measuring sensitivity. Its sensitivity in the F c and F f directions is about five times higher than that of the F p direction.…”

“…The cutting force sensor introduced in this paper is upgraded from our previous work [ 21 , 22 ], Figure 2 c depicts the composition of the sensor: the cutting tool is fixed in the tool slot by screws, and the ESE is in the middle of the senor. MEMS strain gauges are bonded on the ESE for measuring triaxial cutting force F c , F f , and F p , respectively.…”

Cutting Forces Measurement for Milling Process by Using Working Tables with Integrated PVDF Thin-Film Sensors

“…Instrumented tables or components are designed to integrate sensors or to be used as sensors to measure forces and vibrations. Zhao et al [ 10 ] developed a structure with two mutual-perpendicular octagonal rings and three Wheatstone full bridge circuits in order to obtain the tri-axial cutting force components and restrain cross-interference in turning process. Yu et al [ 11 ] proposed a flexible piezoelectric tactile sensor array based on a polyvinylidene fluoride (PVDF) film for measuring three-axis dynamic contact force distribution.…”

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining

“…Zhao et al [51] developed a tri-axial cutting force sensor with high-performance for turning processes. The sensitive element of the sensor was in the shape of two mutual-perpendicular octagonal rings.…”