Abstract
This paper proposes a high-strain sensitivity turning dynamometer that combines several thin-film resistor grids into three Wheatstone full-bridge circuits that can measure triaxial cutting forces. This dynamometer can replace different cutter heads using flange connections. In order to improve the strain effect of the dynamometer, the strain film sensor is fixed on the regular octagonal connection plates on both ends of the elastomer by vacuum brazing, and the stepped groove structure is also designed inside the elastomer. The dynamometer model is simplified as a four-segment cantilever beam which has different sections. The measurement mechanism model of the dynamometer system is established by the transformation relationship between deflection and strain, under external force. The standard turning tool of 20 mm square is used as a reference. The influence of the structural dimensions of the dynamometer on its strain sensitivity coefficient K is studied. The applicability of the theoretical model of dynamometer strain is verified by finite element analysis. Finally, the dynamometer with the largest K value is subjected to the bending test and compared with a standard turning tool. The experimental results show that the measurement sensitivity of the dynamometer is 2.32 times greater than that of the standard turning tool. The results also show that this dynamometer can effectively avoid the influence of the pasting process on strain transmission, thus indicating its great potential for measuring cutting force in the future.
Highlights
As the development of the micromachine field increases rapidly, the requirements for machining accuracy in machine manufacturing are increasing
This paper presents a turning dynamometer embedded in a film strain sensor, which can measure three-way cutting for2ces and has high-strain ys=e1n.9s1i7ti?vi0t-y3x
This paper presents a turning dynamometer embedded in a film strain sensor, which can measure three-way cutting forces and has high-strain sensitivity
Summary
As the development of the micromachine field increases rapidly, the requirements for machining accuracy in machine manufacturing are increasing. Et al proposed a sensor model for measuring triaxial cutting forces [5,6] They used two mutually perpendicular octagonal ring structures as elastic elements. The deformation of each segment can be superimposed to obtain the total displacement of the C section and the D section under the action of the main cutting force Fz: ωC = ωC1 + ωC2 ωD = ωD1 + ωD2 + ωD3. Ii and li (i = 1, 2, 3) are the initial moment of inertia and length of each segment of the dynamometer model, and h is the distance from the sensor to the neutral layer. By integrating the above formulas, the relationship between the output voltages of the three bridge circuits and the cutting force components in the measurement system proposed in this paper can be obtained: K1Fz + K2s sin θFy kαU0. This guidance is significance for improving the measurement sensitivity of the dynamometer after calibrating the force range
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