Abstract
A strain-type three-component table dynamometer is presented in this paper, which reduces output errors produced by cutting forces imposed on the different milling positions of a workpiece. A sensor structure with eight parallel elastic beams is proposed, and sensitive regions and Wheastone measuring circuits are also designed in consideration of eliminating the influences of the eccentric forces. To evaluate the sensor decoupling performance, both of the static calibration and dynamic milling test were implemented in different positions of the workpiece. Static experiment results indicate that the maximal deviation between the measured forces and the standard inputs is 4.58%. Milling tests demonstrate that with same machining parameters, the differences of the measured forces between different milling positions derived by the developed sensor are no larger than 6.29%. In addition, the natural frequencies of the dynamometer are kept higher than 2585.5 Hz. All the measuring results show that as a strain-type dynamometer, the developed force sensor has an improved eccentric decoupling accuracy with natural frequencies not much decreased, which owns application potential in milling process monitoring.
Highlights
Many technologies have been applied to monitor machining processes [1]
A three-component milling dynamometer with eight parallel beams was proposed to reduce the output errors caused by different loading positions in dynamic milling processes
With sensor the output errors caused by different loading positions in dynamic milling processes
Summary
Many technologies have been applied to monitor machining processes [1]. Cutting force is an important indicator to evaluate inconspicuous tool wear, cutting vibrations, chip formation and machining errors during machining processes [2,3,4,5]. Various measuring methods have been tried to obtain its real-time value [6]. With their excellent performance advantages, piezoelectric dynamometers were the most extensively employed instruments [7,8]. Strain-type dynamometers with low manufacturing cost are another feasible milling force measurement method. Based on the strain effect, rotating dynamometers mounted on main spindle and table force sensors placed between the workbench and workpiece were both developed. Because of their few mounting constraint requirements, various types of rotating dynamometers have been proposed too [9,10,11]. Considering the difficulties in prolonging the Sensors 2017, 17, 949; doi:10.3390/s17050949 www.mdpi.com/journal/sensors and as well as enhancing the sensor bandwidth limited by the stiffness of the milling spindle [12,13], table force sensors are mainly studied at this time
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