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Sensors 2016, 16(1), 70; doi:10.3390/s16010070

Design and Analysis of a Sensor System for Cutting Force Measurement in Machining Processes

1
College of Electric and Information Technology, Hunan University, Changsha 410082, Hunan, China
2
State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, Hunan University, Changsha 410082, Hunan, China
3
Lassonde School of Engineering, York University, Toronto, ON M3J 1P3, Canada
4
Institute of Intelligent Machines, Chinese Academy of Science, Hefei 230031, Anhui, China
These authors contributed equally to this work.
*
Authors to whom correspondence should be addressed.
Academic Editors: Lianqing Liu, Ning Xi, Wen Jung Li, Xin Zhao and Yajing Shen
Received: 22 November 2015 / Revised: 30 December 2015 / Accepted: 4 January 2016 / Published: 7 January 2016
(This article belongs to the Special Issue Sensors for Robots)
View Full-Text   |   Download PDF [6011 KB, uploaded 7 January 2016]   |  

Abstract

Multi-component force sensors have infiltrated a wide variety of automation products since the 1970s. However, one seldom finds full-component sensor systems available in the market for cutting force measurement in machine processes. In this paper, a new six-component sensor system with a compact monolithic elastic element (EE) is designed and developed to detect the tangential cutting forces Fx, Fy and Fz (i.e., forces along x-, y-, and z-axis) as well as the cutting moments Mx, My and Mz (i.e., moments about x-, y-, and z-axis) simultaneously. Optimal structural parameters of the EE are carefully designed via simulation-driven optimization. Moreover, a prototype sensor system is fabricated, which is applied to a 5-axis parallel kinematic machining center. Calibration experimental results demonstrate that the system is capable of measuring cutting forces and moments with good linearity while minimizing coupling error. Both the Finite Element Analysis (FEA) and calibration experimental studies validate the high performance of the proposed sensor system that is expected to be adopted into machining processes. View Full-Text
Keywords: cutting force measurement; multi-component; in-process measurement; sensor system cutting force measurement; multi-component; in-process measurement; sensor system
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MDPI and ACS Style

Liang, Q.; Zhang, D.; Coppola, G.; Mao, J.; Sun, W.; Wang, Y.; Ge, Y. Design and Analysis of a Sensor System for Cutting Force Measurement in Machining Processes. Sensors 2016, 16, 70.

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