Abstract
Multi-component force sensors have infiltrated a wide variety of automation products since the 1970s. However, one seldom finds full-component sensor systems available in the market for cutting force measurement in machine processes. In this paper, a new six-component sensor system with a compact monolithic elastic element (EE) is designed and developed to detect the tangential cutting forces Fx, Fy and Fz (i.e., forces along x-, y-, and z-axis) as well as the cutting moments Mx, My and Mz (i.e., moments about x-, y-, and z-axis) simultaneously. Optimal structural parameters of the EE are carefully designed via simulation-driven optimization. Moreover, a prototype sensor system is fabricated, which is applied to a 5-axis parallel kinematic machining center. Calibration experimental results demonstrate that the system is capable of measuring cutting forces and moments with good linearity while minimizing coupling error. Both the Finite Element Analysis (FEA) and calibration experimental studies validate the high performance of the proposed sensor system that is expected to be adopted into machining processes.
Highlights
Computer Numerical Control (CNC) machines are operated by precisely programmed commands and widely used in modern manufacturing industry, enabling the manufacture of complex-shaped products or parts that cannot be produced by manually operated machines.Nowadays, every manufacturer in the global market is pitted against worldwide competitors with consistently improving product quality, enhanced manufacturing productivity, elimination of inspections, and shrinking total machining costs.The condition of cutting tools and the cutting process should be identified without human assistance and/or interrupting the manufacturing process operation, which is one of the most important operating criteria that influences the manufacturing quality and productivity
As precise estimation and determination of cutting force at tool tips in manufacturing processes is the most effective method for monitoring machine tools and the machining processes, it is indispensable in many research and application fields for monitoring the tool conditions, analyzing of machining methods and tools, estimating real-time tool wear [3], designing proper machining tools, characterizing and optimizing manufacturing process and cutting parameters, etc
The strain gauges bonded onto the EE are sensitive to dimensional changes when a cutting The strain gauges bonded onto the EE are sensitive to dimensional changes when a cutting force is applied to the sensor, and their resistances change according to: force is applied to the sensor, and their resistances change according to: 3.1
Summary
Computer Numerical Control (CNC) machines are operated by precisely programmed commands and widely used in modern manufacturing industry, enabling the manufacture of complex-shaped products or parts that cannot be produced by manually operated machines. Within most environments the indirect approach is easier to achieve, but has several limitations such as high computation time, unsuitable for multi-axis cutting process, does not consider the frictional behavior of the machine tools. Many different sensory systems for cutting force measurement have been developed for specific tasks Many tasks such as monitoring and controlling of high speed machining processes require reliable and practical sensing methods to measure the cutting force, which cannot be achieved by the majority of the present sensory systems. This is partially due to limited workpiece sizes, low frequency bandwidths, mounting constraints, wiring complexities, and susceptibility to harsh machining environments [19]. A novel six-component Force/Moment (F/M) sensor is designed to detect the normal and tangential cutting force (Fx, Fy and Fz), as well as the cutting moments (Mx, My and Mz), simultaneously
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