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Performing Microscope-Mounted Y-Shaped Cutting Tests
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A high performance sensor for triaxial cutting force measurement in turning.
You Zhao1, Yulong Zhao2, Songbo Liang3
1The State Key Laboratory for Manufacturing Systems Engineering, Xi'an Jiaotong University, No. 28, Xianning West Road, Xi'an 710049, China. zhaoyou319@stu.xjtu.edu.cn.
Sensors (Basel, Switzerland)
|April 10, 2015
Summary
A novel triaxial cutting force sensor using octagonal rings achieves high accuracy (0.38%-0.83%) for high-speed turning. Its natural frequencies allow for effective real-time force measurement up to 17,205 RPM.
Area of Science:
- Mechanical Engineering
- Sensor Technology
- Manufacturing Processes
Background:
- Accurate measurement of cutting forces is crucial for optimizing high-speed turning processes.
- Existing sensors often face challenges with accuracy, natural frequency, and cross-interference.
Purpose of the Study:
- To develop and validate a high-performance triaxial cutting force sensor for high-speed turning.
- To investigate the sensor's accuracy, natural frequency, and cross-interference characteristics.
Main Methods:
- A novel sensor design utilizing two mutually perpendicular octagonal rings as the sensitive element.
- Integration of three Wheatstone full bridge circuits to measure triaxial forces and minimize cross-interference.
- Static calibration and modal impact testing to evaluate sensor performance.
Main Results:
- Static calibration demonstrated high accuracy within the range of 0.38%-0.83%.
- Natural frequencies were identified as 1147 Hz, 1122 Hz, and 2035 Hz in triaxial directions.
- Real-time measurements during turning showed good agreement with cutting parameter variations.
Conclusions:
- The developed sensor exhibits excellent accuracy, favorable natural frequencies, and acceptable cross-interference.
- The sensor is suitable for high-speed turning applications, supporting spindle speeds up to 17,205 RPM.
- The sensor shows significant potential for real-time cutting force measurement in turning operations.
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