Broaching Load Testing System Based On Strain Sensor

Broaching provided greater cutting force and high precision metal parts machining,which was broaching compared to other metal was irreplaceable advantages.When broaching the workpiece,detecting broaching force could detection the working condition of broach,early discoveried tool wear,and reduced the risk of cutting tool's rupture.So on the broaching force detection is of great significance.On this basis,this paper based on the research of the strain sensor,proposing a broaching force detection device based on strain sensor.Designed the amplifier of strain sensor and established signal acquisition device on the basis of the PLC.The article also established a model of broach under static load,and found out the relationship between stress and the location of the broach.Through the simulation of Ansys software,calibration experiment of detection system was designed to calculate the sensitivity of detection device.And under different conditions to implement broaching force testing experiment,the experimental results were analyzed.In the first chapter,the article introduced the domestic and foreign scholars researched on cutting force detection,and mainly introduced the strain type and voltage type of cutting force detection device.And the article analysed the deficiency of research technology,then introduced the main work content in this paper.In the second chapter,the composition of broaching force detection system are introduced,and the working principle of strain sensor was analyzed.Then the article illustrated the hardware composition of testing system and selected models and analyzed the strain gauge on the broach the reasonable location of the patch.Amplifying circuit of the strain sensor was designed and tested the performance of the amplifier circuit.Broaching force detection system based on PLC was designed the collection procedures,written a computer program based on c + + builder.In the third chapter,first the article established the broach stress under the static load model,The static model of broach was established and found the relationship between the stress and the position on the principle of mechanics of elasticity.Second,broach had carried on the finite element analysis with Ansys software,And the simulation model was obtained under the relationship between the stress and the location.Then the article Compared with the relationship between the theoretical model and simulation model,and provided a theoretical basis for broaching force test device.In the fourth chapter,the article designed a calibration experiment of broaching force detection device.The sensitivity of detection device and nonlinear error of the broaching force was obtained.Broaching force detection device with the traditional hydraulic and broaching force measurement method used in the article were tested under the same conditions.and analyzed the difference between them.We study the accuracy and reliability of the device in this paper.The broaching force detection device verified by testing in different speed of broaching and strain patches at the position and different artifacts.The difference of the experimental results under different conditions were analyzed.And the difference of the experimental results were analyzed under different conditions.In the fifth chapter,the article summarized the main research work,and analyzed the deficiency of broaching force detection device in this paper.Then pointed out the development direction of this system.