Abstract
Cutting force measurement is a quintessential task for status monitoring during machining. In the past, a number of cutting force sensors have been developed, each featuring a different set of performance advantages. In a pursuit to improve the measuring sensitivity and reduce the cross-interference error, in this paper we propose a triaxial cutting force sensor based on a commercial micro-electro-mechanical system (MEMS) strain gauge. An elastic-sensitive element comprised of two mutual-perpendicular octagonal rings is designed for triaxial cutting force measurement, and a decoupling matrix is derived from static calibration to reduce cross-interference. It can be concluded from static calibration that the sensor’s sensitivity is 0.32 mV/N, 0.32 mV/N, and 0.05 mV/N in triaxial directions, and the proposed decoupling matrix is able to reduce cross-interference error to 0.14%, 0.25%, and 4.42%. Dynamic cutting force measurement shows that the cutting force sensor can reflect the variation of cutting status very well, it is qualified to measure triaxial cutting forces in practical applications.
Highlights
Cutting force is closely related to machining accuracy, cutting vibration, heat generation, and tool wear during metal machining [1,2], it reflects every slight change in machining status, and it is a significant factor that influences surface roughness, energy consumption, tool life, etc
Measuring cutting force is an effective method for machining condition monitoring in intelligent manufacturing [3] and can provide data support for cutting fault prediction, tool life research, and cutting parameter optimization [4,5]
Researchers have substantially contributed to inhibiting cross-interference error; for example, the authors of [14] introduced a strain gauge cutting force sensor with a cross-interference error in the range of 0.54–9.25%, and the KISTLER piezoelectric cutting force sensor’s
Summary
Cutting force is closely related to machining accuracy, cutting vibration, heat generation, and tool wear during metal machining [1,2], it reflects every slight change in machining status, and it is a significant factor that influences surface roughness, energy consumption, tool life, etc. Yaldiz et al has reported a strain gauge cutting force sensor whose sensitivity is 0.082 mV/N, 0.122 mV/N, and 0.119 mV/N in triaxial directions [14]. Researchers have substantially contributed to inhibiting cross-interference error; for example, the authors of [14] introduced a strain gauge cutting force sensor with a cross-interference error in the range of 0.54–9.25%, and the KISTLER piezoelectric cutting force sensor’s (type 9219A). A triaxial cutting force sensor using a commercial MEMS strain gauge in order to achieve high sensitivity is introduced, and a decoupling matrix method is proposed to reduce cross-interference error. Details on the sensor design, fabrication, and performance test will be introduced
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