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Sensors 2017, 17(5), 949; doi:10.3390/s17050949

Design and Development of a Three-Component Force Sensor for Milling Process Monitoring

1
The State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an 710049, China
2
School of EMU Application and Maintenance Engineering, Dalian Jiaotong University, Dalian 116028, China
3
Shaanxi Key Laboratory of Nano Materials and Technology, Xi’an University of Architecture and Technology, Xi’an 710055, China
*
Author to whom correspondence should be addressed.
Academic Editor: Vittorio M. N. Passaro
Received: 16 March 2017 / Revised: 18 April 2017 / Accepted: 21 April 2017 / Published: 25 April 2017
(This article belongs to the Section Physical Sensors)
View Full-Text   |   Download PDF [13543 KB, uploaded 25 April 2017]   |  

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. View Full-Text
Keywords: table dynamometer; strain type; positional variation; milling force decoupling table dynamometer; strain type; positional variation; milling force decoupling
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Li, Y.; Zhao, Y.; Fei, J.; Qin, Y.; Zhao, Y.; Cai, A.; Gao, S. Design and Development of a Three-Component Force Sensor for Milling Process Monitoring. Sensors 2017, 17, 949.

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