Design and Development of a Three-Component Force Sensor for Milling Process Monitoring

Li, Yingxue; Zhao, Yang; Fei, Jiyou; Qin, Yafei; Zhao, You; Cai, Anjiang; Gao, Song

doi:10.3390/s17050949

Cited by 14 publications

(7 citation statements)

References 16 publications

(17 reference statements)

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“…Yu et al [ 11 ] proposed a flexible piezoelectric tactile sensor array based on a polyvinylidene fluoride (PVDF) film for measuring three-axis dynamic contact force distribution. Li et al [ 12 ] presented a strain-type three-component table dynamometer with has a sensor structure with eight parallel elastic beams and sensitive regions and Wheastone measuring circuits are designed to eliminate the influence of eccentric forces. To monitor the machining process, Shi and Gindy [ 13 ] integrated the strain sensor, accelerometer and power sensor into the machine tool to detect tool malfunctions for machining processes.…”

Section: Introductionmentioning

confidence: 99%

Cutting Forces Measurement for Milling Process by Using Working Tables with Integrated PVDF Thin-Film Sensors

Luo

Chong

Liu

2018

Sensors

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In the milling process, cutting forces contain key information about the machining process status in terms of workpiece quality and tool condition. On-line cutting force measurement is key for machining condition monitoring and machined surface quality assurance. This paper presents a novel instrumented working table with integrated polyvinylidene fluoride (PVDF) thin-film sensors, thus enabling the dynamic milling force measurement with compact structures. To achieve this, PVDF thin-film sensors are integrated into the working table to sense forces in different directions and the dedicated cutting force decoupling model is derived. A prototype instrumented working table is developed and validated. The validation demonstrates that profiles of the forces measured from the developed instrumented working table prototype and the dynamometer match well. Furthermore, the milling experiment results convey that the instrumented working table prototype could also identify the tool runout due to tool manufacturing or assembly errors, and the force signal spectrum analysis indicates that the developed working table can capture the tool passing frequency correctly, therefore, is suitable for the milling force measurement.

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Section: Introductionmentioning

confidence: 99%

Cutting Forces Measurement for Milling Process by Using Working Tables with Integrated PVDF Thin-Film Sensors

Luo

Chong

Liu

2018

Sensors

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“…The material used in the design is with elastic modulus E = 200GPa and yield strength σ S = 2020MPa. According to the impact factor n c = 1:5 and safety factor n a = 2 selected in [8], the allowable stress can be obtained ½σ = 673MPa.…”

Section: Definition Of Materials Properties and Boundarymentioning

confidence: 99%

“…According to the strain cloud diagram and strain value distribution diagram [9][10][11], the installation position of the strain gauge is determined by comprehensively considering the paste technique and sensitivity requirements of the strain gauge. Wheatstone bridge was designed reasonably to achieve the largest possible output for the measured component [8] and the smallest possible output signal for other components, as well as achieve the electrical decomposition of force and torque. The final distribution of strain gauges and bridge formation are shown in Figures 8 and 9.…”

Section: Strain Gauge Position and Groupmentioning

confidence: 99%

Multiobjective Optimization of Structure and Robustness of a Split Parallel Multicomponent Strain Sensor

Kong

Peng

Lian

2022

Wireless Communications and Mobile Computing

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A novel split parallel multicomponent strain sensor structure layout is proposed based on the special requirements of the helicopter rotor airfoil wind tunnel test for measuring aerodynamic sensors. The sensor consists of two splits with the same configuration; the performance of the sensor not only depends on the split structure of the sensor but also depends on the assembly relationship between the splits. Three steps have been performed so as to enhance the technical performance of the sensor. First, the RBF neural network approximate model and the second-generation nondominated sorting genetic algorithm are used to optimize the split of sensor deterministically; secondly, the rotor airfoil wind tunnel test model and the sensor finite element system model are established, and the 6 σ robustness analysis is carried out; finally, the 6 σ robust multiobjective optimization has been carried out considering the sensor split processing errors and the assembly errors. The results show that, compared to initial designed sensors, the sensitivity of the three components of the sensor is increased by 285.46%, 284.95%, and 151.5%, respectively, and the maximum equivalent stress is reduced by 28.4%; the interference to the three components is reduced by 97.82%, 92.83%, and 99.8%, respectively, and the quality is reduced by 25.74%. Meanwhile, the quality level of the sensor was promoted, and the sensitivity of the response to assembly and manufacturing errors were reduced. These results exhibit that the structural layout, optimized path, and method in this strain sensor are suitable for the needs of helicopter rotor airfoil wind tunnel test.

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“…There are six sensors strategically placed around the table to measure pressure in all three dimensions. Li et al [24] developed a strain-type, three-component table dynamometer by mounting a strain gauge on eight parallel elastic beams. These beams were deployed to increase the stiffness, and the construction of the vertical beam was adjusted to minimize the effect of eccentric force on the measurement result.…”

Section: Introductionmentioning

confidence: 99%

Design and Optimization of a Cross-Beam Force Transducer for a Stationary Dynamometer for Measuring Milling Cutting Force

Rizal¹,

Ghani²,

Usman³

et al. 2023

Journal of Machine Engineering

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This paper's objective is to design and optimize a force transducer to build a stationary dynamometer that can measure three axes of milling cutting force. To reduce interference error and increase sensitivity, the force transducer's Maltese cross-beam design was optimized. The force transducer's performance depends on three design parameters: the cross-rectangular beam's through-hole length and width, the compliant plate thickness, and the strain, stress, and stiffness of force transducer constructions calculated by ANSYS. The response surface method (RSM) estimates a desired second-order polynomial function for three geometric parameters based on sensitivity, interference error, safety factor, and stiffness. A stationary dynamometer prototype was made with four optimized force transducers and several piezoresistive strain sensors. The developed dynamometer has good linearity, repeatability, and hysteresis, as well as high sensitivities and low cross-sensitivity errors. The reference dynamometer's cutting force measurements were very close to those of the designed dynamometer in the validation test.

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Design and Development of a Three-Component Force Sensor for Milling Process Monitoring

Cited by 14 publications

References 16 publications

Cutting Forces Measurement for Milling Process by Using Working Tables with Integrated PVDF Thin-Film Sensors

Cutting Forces Measurement for Milling Process by Using Working Tables with Integrated PVDF Thin-Film Sensors

Multiobjective Optimization of Structure and Robustness of a Split Parallel Multicomponent Strain Sensor

Design and Optimization of a Cross-Beam Force Transducer for a Stationary Dynamometer for Measuring Milling Cutting Force

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