Accurate Cutting-Force Measurement with Smart Tool Holder in Lathe

Cutting force in lathe work is closely related to tool wear and affects the turning quality. Direct measurement of the cutting force by measuring the strain of the tool holder is challenging because the tool holder design aims to be highly rigid in order to undertake large cutting forces. Accordingly, the most popular dynamometer designs modify the standard tool holder by decreasing the structural rigidity of the holder, which reduces the machining precision and is not widely accepted. In order to solve the issue of the low stiffness of the dynamometer reducing the machining precision, in this paper, the ultra-low strain on the tool holder was successfully detected by the highly sensitive semiconductor strain gauges (SCSG) adjacent to the blade cutting insert. However, the cutting process would generate much heat, which increases the force measuring area temperature of the tool holder by about 30 °C. As a result, the readout drifted significantly with the temperature changes due to the high temperature coefficient of SCSG. To solve this problem, the temperature on the tool holder was monitored and a BP neural network was proposed to compensate for temperature drift errors. Our methods improved the sensitivity (1.14 × 10−2 mV/N) and the average relative error of the BP neural network prediction (≤1.48%) while maintaining the original stiffness of the tool holder. The smart tool holder developed possesses high natural frequency (≥6 kHz), it is very suitable for dynamic cutting-force measurement. The cutting experiment data in the lathe work show comparable performance with the traditional dynamometers and the resolution of the smart tool holder is 2 N (0.25% of total range).

[1]  I. Gibson,et al.  Laser subtractive and laser powder bed fusion of metals: review of process and production features , 2023, Rapid Prototyping Journal.

[2]  A. Fernández-Valdivielso,et al.  Threading holder based on axial metal cylinder pins to reduce tap risk during reversion instant , 2022, Alexandria Engineering Journal.

[3]  Yuan-Liu Chen,et al.  Three-axial cutting force measurement in micro/nano-cutting by utilizing a fast tool servo with a smart tool holder , 2021 .

[4]  Kai Guo,et al.  An integrated wireless vibration sensing tool holder for milling tool condition monitoring with singularity analysis , 2021 .

[5]  Zhengyou Xie,et al.  A multi-sensor integrated smart tool holder for cutting process monitoring , 2020, The International Journal of Advanced Manufacturing Technology.

[6]  Yusri Yusof,et al.  Machine monitoring system: a decade in review , 2020, The International Journal of Advanced Manufacturing Technology.

[7]  Dong Wang,et al.  Integrated cutting force measurement system based on MEMS sensor for monitoring milling process , 2020 .

[8]  Zude Zhou,et al.  Smart Cutting Tool Integrated With Optical Fiber Sensors for Cutting Force Measurement in Turning , 2020, IEEE Transactions on Instrumentation and Measurement.

[9]  Maria Luisa Grilli,et al.  The Critical Raw Materials in Cutting Tools for Machining Applications: A Review , 2020, Materials.

[10]  Dongsheng Liu,et al.  Cutting Forces Measurement for Milling Process by Using Working Tables with Integrated PVDF Thin-Film Sensors , 2018, Sensors.

[11]  Ming Luo,et al.  A wireless instrumented milling cutter system with embedded PVDF sensors , 2018, Mechanical Systems and Signal Processing.

[12]  Li Xiao,et al.  Development and Testing of an Integrated Rotating Dynamometer Based on Fiber Bragg Grating for Four-Component Cutting Force Measurement , 2018, Sensors.

[13]  Y Zhao,et al.  Research of a smart cutting tool based on MEMS strain gauge , 2018 .

[14]  Jianguang Li,et al.  Development and testing of an integrated smart tool holder for four-component cutting force measurement , 2017 .

[15]  Kai Cheng,et al.  Smart Cutting Tools and Smart Machining: Development Approaches, and Their Implementation and Application Perspectives , 2017 .

[16]  M. S. Uddin,et al.  On the design and analysis of an octagonal–ellipse ring based cutting force measuring transducer , 2016 .

[17]  You Zhao,et al.  A High Performance Sensor for Triaxial Cutting Force Measurement in Turning , 2015, Sensors.

[18]  Hui Ding,et al.  Design of an innovative smart turning tool with application to real-time cutting force measurement , 2015 .

[19]  R. Rakowski,et al.  Development of a novel surface acoustic wave (SAW) based smart cutting tool in machining hybrid dissimilar material , 2014 .

[20]  Chao Wang,et al.  Design of an instrumented smart cutting tool and its implementation and application perspectives , 2014 .

[21]  Chao Wang,et al.  Adaptive smart machining based on using constant cutting force and a smart cutting tool , 2013 .

[22]  Kai Cheng,et al.  Design and analysis of a piezoelectric film embedded smart cutting tool , 2013 .

[23]  E. Díaz-Tena,et al.  Propagation of assembly errors in multitasking machines by the homogenous matrix method , 2013 .

[24]  John B. Morehouse,et al.  Thin-Film PVDF Sensor-Based Monitoring of Cutting Forces in Peripheral End Milling , 2012 .

[25]  Guido Wirtz,et al.  Development of a dynamometer for measuring individual cutting edge forces in face milling , 2010 .

[26]  I. Rajendran,et al.  Design and development of strain gauge based milling tool dynamometer , 2010 .

[27]  Aitzol Lamikiz,et al.  Recording of real cutting forces along the milling of complex parts , 2006 .

[28]  Zbigniew J. Pasek,et al.  CUTTING PROCESS DIAGNOSTICS UTILISING A SMART CUTTING TOOL , 2002 .

[29]  C. Hopkins,et al.  A Review of Developments in the Fields of the Design of Smart Cutting Tools, Wear Monitoring, and Sensor Innovation , 2019, IFAC-PapersOnLine.

[30]  Welf-Guntram Drossel,et al.  Performance of a new piezoceramic thick film sensor for measurement and control of cutting forces during milling , 2018 .

[31]  Xuefeng Chen,et al.  The concept and progress of intelligent spindles: A review , 2017 .

[32]  Rahul Jain,et al.  Design, Development and Testing of a Three Component Lathe Tool Dynamometer Using Resistance Strain Gauges , 2016 .

[33]  R. L. Hannah,et al.  Strain gage users' handbook , 1992 .