Design and analysis of a sensor system for cutting force measurement in machining processes

Multi-component force sensors have infiltrated a wide variety of automation products since the 1970s. However, one seldom finds full-component sensor systems available in the market for cutting force measurement in machine processes. In this paper, a new six-component sensor system with a compact monolithic elastic element (EE) is designed and developed to detect the tangential cutting forces Fx, Fy and Fz (i.e., forces along x-, y-, and z-axis) as well as the cutting moments Mx, My and Mz (i.e., moments about x-, y-, and z-axis) simultaneously. Optimal structural parameters of the EE are carefully designed via simulation-driven optimization. Moreover, a prototype sensor system is fabricated, which is applied to a 5-axis parallel kinematic machining center. Calibration experimental results demonstrate that the system is capable of measuring cutting forces and moments with good linearity while minimizing coupling error. Both the Finite Element Analysis (FEA) and calibration experimental studies validate the high performance of the proposed sensor system that is expected to be adopted into machining processes.