Design Study of Double Parallel Beam Cutting Force Sensor

Abstract

Real-time monitoring of the cutting force during the cutting process is crucial. In the past, cutting force sensors of various structures have been developed, and to improve the integrality and reduce the cross-interference error, a double-parallel-beam cutting force sensor is designed in this study. Through theoretical analysis and finite element method to analyze the influence of each factor on the performance of the sensor, to determine the optimal parameters of the sensor, to fabricate the prototype, and to carry out the patch, group bridge, and package on the double parallel beam. Then the performance test is carried out, and the results show that the sensitivities of the double parallel beam cutting force sensor in the two directions of main cutting force F_c and feed force F_f are 4.11 × 10⁻³ mV/N and 4.75 × 10⁻³ mV/N, respectively, and the minimum cross-interference error is only 0.88%; finally, the cutting test is carried out, and the designed cutting force sensor exhibits a satisfactory ability to accurately measure and record the cutting force under different cutting parameters.