title: Design and Analysis of a Sensor System for Cutting Force Measurement in Machining Processes.
abstract: 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.
authors.affiliation: College of Electric and Information Technology, Hunan University, Changsha 410082, Hunan, China. qiaokang@hnu.edu.cn.|State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, Hunan University, Changsha 410082, Hunan, China. qiaokang@hnu.edu.cn.
authors.forename: Qiaokang
authors.initials: Q
authors.lastname: Liang
authors.affiliation: Lassonde School of Engineering, York University, Toronto, ON M3J 1P3, Canada. dan.zhang@lassonde.yorku.ca.
authors.forename: Dan
authors.initials: D
authors.lastname: Zhang
authors.affiliation: Lassonde School of Engineering, York University, Toronto, ON M3J 1P3, Canada. Gianmarc.Coppola@uoit.ca.
authors.forename: Gianmarc
authors.initials: G
authors.lastname: Coppola
authors.affiliation: College of Electric and Information Technology, Hunan University, Changsha 410082, Hunan, China. mao_jianxu@126.com.
authors.forename: Jianxu
authors.initials: J
authors.lastname: Mao
authors.affiliation: College of Electric and Information Technology, Hunan University, Changsha 410082, Hunan, China. wei-sun@hnu.edu.cn.|State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, Hunan University, Changsha 410082, Hunan, China. wei-sun@hnu.edu.cn.
authors.forename: Wei
authors.initials: W
authors.lastname: Sun
authors.affiliation: College of Electric and Information Technology, Hunan University, Changsha 410082, Hunan, China. yaonan@hnu.edu.cn.|State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, Hunan University, Changsha 410082, Hunan, China. yaonan@hnu.edu.cn.
authors.forename: Yaonan
authors.initials: Y
authors.lastname: Wang
authors.affiliation: Institute of Intelligent Machines, Chinese Academy of Science, Hefei 230031, Anhui, China. yjge@iim.ac.cn.
authors.forename: Yunjian
authors.initials: Y
authors.lastname: Ge
keywords: cutting force measurement; in-process measurement; multi-component; sensor system