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Related Experiment Video

Updated: Mar 29, 2026

Performing Microscope-Mounted Y-Shaped Cutting Tests

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Published on: January 20, 2023

Spindle-Integrated Three-Axis Cutting Force Measurement System for Ultra-Precision Diamond Milling.

Zhongwei Li¹, Liang An¹, Yuqi Ding¹

¹The State Key Lab of Fluid Power and Mechatronic Systems, Zhejiang University, Hangzhou 310027, China.

Sensors (Basel, Switzerland)

|March 28, 2026

Summary

This study introduces a new method for measuring cutting forces during ultra-precision diamond milling. The developed system accurately monitors forces, enabling high-precision tool setting for advanced manufacturing.

Keywords:

cutting force measurement piezoelectric force sensor ultra-precision diamond milling

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Area of Science:

Manufacturing Engineering
Materials Science
Mechanical Engineering

Background:

Ultra-precision diamond milling is essential for creating complex precision components.
Effective machining process monitoring is key to enhancing product quality.
Existing methods may lack the precision required for micro-scale manufacturing.

Purpose of the Study:

To develop and validate a spindle-integrated three-axis cutting force measurement method for ultra-precision diamond milling.
To enable real-time monitoring and control of the milling process.
To improve the accuracy and efficiency of precision component manufacturing.

Main Methods:

Designed a novel spindle-integrated force measurement mechanism with four symmetrically arranged piezoelectric force sensors.
Performed calibration tests to assess linearity and accuracy (less than 2% deviation).
Implemented a Wiener filter to mitigate noise from vibrations and inertial forces.

Main Results:

Achieved precision tool-setting in the Z-direction with accuracy below 100 nm.
Demonstrated effective detection of cutting forces as low as 50 mN.
Showcased strong correlation between the developed system and commercial dynamometers.

Conclusions:

The proposed spindle-integrated force measurement system offers a promising and effective in-process monitoring solution for ultra-precision diamond milling.
This technology facilitates enhanced machining quality and precision component fabrication.
The system's ability to detect low forces and its accuracy make it valuable for micro-manufacturing applications.