Determination of sensor location for cutting tool deflection using finite element method simulation

Abstract

The aim of this study was to determine the the optimum locations to mount the sensor for measuring the cutting tool deflection during turning process using finite element method simulation. In this study, stress analysis had been conducted using Autodesk Inventor Professional 2010 integrated with ANSYS software. The simulation results were validated using a strain gauge as the sensor for the detection of cutting force signal during the turning of hardened plain carbon steel JIS S45C using carbide tool. Two strain gauges were mounted on the tool holder at two defined locations I and II, at distances of 37 and 47 mm, respectively, from the cutting point. Only one set of cutting parameters was conducted at spindle speed, N = 1000 rpm, feed, f = 0.25 mm/rev and depth of cut, d = 0.80 mm. The turning process was stopped and the insert discarded when the average flank wear, VBm, reached 0.30 mm. The main cutting force, Fy, and the feed force, Fx, for each machining run were measured, collected and analysed at locations I and II. It was found that when strain gauges were placed at a distance of approximately 43 mm from the cutting point, it was the optimum location for sensing the cutting force signals.