Bridging Cost and Performance in Cutting Force Measurement: A PVDF-Based Universal Plate Dynamometer.

Area of Science:

• Mechanical Engineering
• Materials Science

Background:

• Cutting force measurement is crucial in machining.
• Existing dynamometers have limitations in cost, stiffness, and bandwidth.
• Strain gauges are cheap but flexible; piezoelectric sensors are accurate but costly.

Purpose of the Study:

• To design, construct, and validate a novel plate dynamometer using polyvinylidene fluoride (PVDF) sensors.
• To offer an intermediate-cost solution for advanced milling applications.
• To bridge the performance gap between low-cost and high-performance dynamometers.

Main Methods:

• Finite-element analysis for structural validation.
• Integration of eight PVDF films and four accelerometers.
• Modal testing and application of the Universal Inverse Filter (UIF).
• Validation through milling tests under various cutting conditions.

Main Results:

• FEA confirmed favorable stress distribution and high resonance frequencies.
• UIF extended the usable bandwidth to 5 kHz (direct) and 0.3-4 kHz (cross-directions).
• The PVDF dynamometer approached piezoelectric device performance.
• Successful validation in diverse milling tests.

Conclusions:

• The novel PVDF plate dynamometer provides a versatile, intermediate-cost solution for machining research and industry.
• It offers a practical alternative to existing dynamometer technologies.
• The device shows promise for advanced milling applications requiring good dynamic performance.