Abstract
This paper presents a dynamically compensated Spindle Integrated Force Sensor (SIFS) system to measure cutting forces. Piezo-electric force sensors are integrated to the stationary spindle housing. The structural dynamic model between the cutting forces acting on the tool tip and the measured forces at the spindle housing is identified. The system is first calibrated to compensate the influence of spindle run-out and unbalance at different speeds. Using both the cutting force and acceleration sensor signals measured at the spindle housing, a Kalman Filter is designed to filter the influence of structural modes on the force measurements. The frequency bandwidth of the proposed sensor system is expanded from 300 Hz to about 800 Hz with the proposed sensing and the signal processing method.
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