Cutting Forces in Machining and Their Routine Measurement with Multi-Component Piezo-Electric Force Transducers

Stability Evaluation for a Damped, Constrained-Motion Cutting Force Dynamometer

“…The mechanics of the milling process have been extensively studied; in this context, the cutting force is a considerable area of research interest. As a result of the high sensitivity and rapid response of the cutting force signal to changes in cutting condition [4][5][6][7][8], the force signal can be processed for various tasks to optimize machine tool usage, such as: (1) adaptive feed rate control to keep the applied force at a predetermined level [1][2][3][4]; (2) tool wear evaluation from a comparative force level [9][10][11][12][13]; (3) force monitoring for the detection of chatter vibrations [1,2,[4][5][6][7][8][9][10][11][12][13]; and (4) force monitoring for the detection of tool breakage in milling [9][10][11][12][13].…”

“…The dynamometer's measurand, in this case, force, must be transformed into a physical quantity with a known input-output relationship which is realized by at least one principle of measurement in the transducer; see Table 1. Cutting forces are always estimated by using indirect methods, i.e., by measuring the effects of cutting forces such as local deformations, displacements, or accelerations of mechanical elements composing the machining system [8][9][10]. In practice, multi-axis dynamometers based on piezoelectric sensors provide the most common solution for cutting force measurement.…”

“…In practice, multi-axis dynamometers based on piezoelectric sensors provide the most common solution for cutting force measurement. A typical dynamometer consists of three or four piezoelectric transducers compressed under high preloads between two stiff plates [8,9]. The transducers consist of thin slabs of the piezoelectric material cut in a precise orientation to the crystal axes depending on the application [10].…”

“…The transducers consist of thin slabs of the piezoelectric material cut in a precise orientation to the crystal axes depending on the application [10]. The dynamic deflections of the dynamometer's piezoelectric transducers during machining operations produce a charge which is converted into a voltage proportional to the force that caused the deformation [1,2,[8][9][10]. During the machining process, the boundary conditions of the dynamometer such as the connection to the machine tool structure and size and placement of the work material on the dynamometer will lead to variations in the structural response of the dynamometer system.…”

Improved inverse filter for the correction of distorted measured cutting forces

“…Typical table dynamometer is made up of piezoelectric sensors which are assembled between two plates [3]. However, because of dynamic characteristics of cutting force measuring system, sometimes cutting force measured from table dynamometer will be distorted and cannot accurately reflect the actual physical property of machining process [4].…”