Development and Testing of a High-Frequency Dynamometer for High-Speed Milling Process

Abstract

Cutting forces are strongly associated with the mechanics of the cutting process. Hence, machining forces measurements are very important to investigate the machining process, and numerous methods of cutting forces measurements have been applied. Nowadays, a dynamometer is the most popular tool for cutting forces measurements. However, the natural frequency of a dynamometer has a direct impact on the accuracy of measured cutting forces in the machining process. Therefore, few dynamometers are appropriate and reliable to measure the cutting forces at high frequencies. In this work, a new strain-gauge-based dynamometer (SGBD) with a special structure was designed, manufactured, and put to the test to ensure the measurement of high-frequency dynamic forces in the milling process. The main structure of the SGBD is symmetrical and mainly consists of a center quadrangular prism surrounded by four force sensing elastic elements, an upper support plate, and a lower support plate. The dynamic identification test was conducted and indicated that the SGBD′s natural frequency could be stabilized at a high value of 9.15 kHz. To automatically obtain the milling force data with a computer during high rotational speed milling, a data acquisition system was devised for the dynamometer. To reduce the effects of cross-sensitivity and acting point of force, an innovative model based on a conversion matrix was established for the dynamometer. Furthermore, the cutting tests were conducted at high rotational speeds (10,000–18,000 rpm), and it was found that the difference of cutting forces between the SGBD and a Kistler dynamometer are 2.3–5.8% in the X direction and 3.5–8.8% in the Y direction. The experimental findings disclosed that the new kind of dynamometer is reliably for the measurement of high-frequency dynamic forces in milling at high rotational speeds.

Data-Driven Remaining Useful Life Estimation for Milling Process: Sensors, Algorithms, Datasets, and Future Directions

“…It provides cutting forces to describe the cutting process state during machining [78]. It shows an excellent response to cutting forces due to its high reliability and sensitivity.…”

Self-sensing tool holder for in-process metrology of cutting force in ultra-high-precision single-point diamond turning applications

“…It has shown that reducing the cutting forces can improve the tool life and decrease the tool wear [4,5]. The measurement of cutting forces is often used as an indicator in the design of a machine tool and to optimize the cutting mechanisms [6,7].…”

“…Rizal et al [6], developed a force sensing system in which strain gauges were mounted on the structure and integrated to a tool holder, to monitor three cutting forces during the milling process. In other studies, a strain gauge-based torque measurement systems, called a smart tool holder, have been designed and developed.…”

Parametric Optimization for Cutting Forces and Material Removal Rate in the Turning of AISI 5140

“…The resultant cutting force is divided into three components of cutting force in a simple turning operation: tangential (F C ), axial (F F ) and radial (F R ). The motive for measuring the cutting forces in machining operations comes from their major effect on cutting tool wear, cutting temperatures, the vibration mechanism and consequently the surface texture of the workpiece [12,13]. As such, cutting forces are one of the significant characteristics in machining operations [14,15].…”