Abstract
In manufacturing process, the stability of cutting state is especially important for processing quality. Monitoring cutting force is a research hotspot for a long time. In this paper, an integrated cutting force measurement system based on piezoresistive MEMS sensor for measuring axial force and torque in milling process is proposed. Based on the thin-walled cylinder and the arch structure, the stress-transforming element of composite splitted structure of conical and cylindrical shell is developed to detect cutting force. The natural frequency of the proposed element has a great improvement in strain sensing sensitivity that can satisfy most cutting situations. A piezoresistive MEMS sensor designed as sensitive component and used in the cutting force measurement system. When the elastic body was sustained cutting force, the piezoresistive MEMS sensors that arranged on the element sense the deformation and output voltage signals to reveal the change of cutting force. In order to verify the basic performance of the cutting force measurement system, static calibration and modal impact tests are carried out. The results indicate that the sensor’s original sensitivity is 2.85 × 10−2 mV/N and 2.90 mV/Nm in axial and torsional directions. Dynamic cutting tests show that the cutting force measurement system can reflect the variation of cutting status very well. It is qualified to monitor the change of axial and torsional forces in practical applications. The cutting test results indicate the measurement system scarcely reduce the workpiece surface quality in machining process.
Similar content being viewed by others
References
Cen L, Melkote SN, Castle J et al (2016) A wireless force-sensing and model-based approach for enhancement of machining accuracy in robotic milling. IEEE/ASME Trans Mechatron 21(5):2227–2235
Dini G, Tognazzi F (2007) Tool condition monitoring in end milling using a torque-based sensorized tool holder. Proc Inst Mech Eng Part B J Eng Manuf 221:11–23
Karabay S (2007) Analysis of drill dynamometer with octagonal ring type transducers for monitoring of cutting forces in drilling and allied process. Mater Des 28(2):673–685
Korkut I (2003) A dynamometer design and its construction for milling operation. Mater Des 24(8):631–637
Li Y, Zhao Y, Fei J et al (2016) Development of a tri-axial cutting force sensor for the milling process. Sensors 16(3):405
Li Y, Zhao Y, Fei J et al (2017) Design and development of a three-component force sensor for milling process monitoring. Sensors 17(5):949
Liang Q, Zhang D, Coppola G et al (2016) Design and analysis of a sensor system for cutting force measurement in machining processes. Sensors 16(1):70
Liu M, Zhou Z, Tao X et al (2012) A dynamometer design and analysis for measurement the cutting forces on turning based on optical fiber Bragg Grating sensor. In: Proceedings of the 10th World Congress on intelligent control and automation. IEEE, pp 4287–4290
Liu M, Zhang Z, Zhou Z et al (2015) A new method based on fiber Bragg grating sensor for the milling force measurement. Mechatronics 31:22–29
Luo M, Luo H, Axinte D et al (2018) A wireless instrumented milling cutter system with embedded PVDF sensors. Mech Syst Signal Process 110:556–568
Ma L, Melkote SN, Morehouse JB et al (2012) Thin-film PVDF sensor-based monitoring of cutting forces in peripheral end milling. J Dyn Syst Meas Control 134(5):051014
Marinescu I, Axinte DA (2008) A critical analysis of effectiveness of acoustic emission signals to detect tool and workpiece malfunctions in milling operations. Int J Mach Tools Manuf 48(10):1148–1160
Qin Y, Zhao Y, Li Y et al (2017) A novel dynamometer for monitoring milling process. Int J Adv Manuf Technol 92(5–8):2535–2543
Rizal M, Ghani JA, Nuawi MZ, Che Haron CH (2015) Development and testing of an integrated rotating dynamometer on tool holder for milling process. Mech Syst Signal Process 52–53:559–576
Subasi O, Yazgi SG, Lazoglu I (2018) A novel triaxial optoelectronic based dynamometer for machining processes. Sens Actuators A Phys 279:168–177
Tognazzi F, Porta M, Failli F et al (2005) A preliminary study on a torque sensor for tool condition monitoring in milling. Springer, Vienna
Wang C, Cheng K, Chen X et al (2014) Design of an instrumented smart cutting tool and its implementation and application perspectives. Smart Mater Struct 23(3):035019
Xie Z, Lu Y, Li J (2017) Development and testing of an integrated smart tool holder for four-component cutting force measurement. Mech Syst Signal Process 93:225–240
Yaldız S, Ünsaçar F, Sağlam H et al (2007) Design, development and testing of a four-component milling dynamometer for the measurement of cutting force and torque. Mech Syst Signal Process 21(3):1499–1511
Acknowledgements
This research is supported by the National High Technology Research and Development Program of China (Grant Nos. 2013AA04110, 2013AA041108), National Science Fund for Distinguished Young Scholars (Grant No. 51325503), Introducing Talent Scientific Research Foundation of Kunming University of Science and Technology (Grant No. KKSY201801003).
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Qin, Y., Wang, D. & Yang, Y. Integrated cutting force measurement system based on MEMS sensor for monitoring milling process. Microsyst Technol 26, 2095–2104 (2020). https://doi.org/10.1007/s00542-020-04768-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00542-020-04768-y