Research On The Three-Dimensional Cutting Force Sensor With Orthogonal Decagonal Ring

Cutting force is an important parameter affecting the cutting quality of workpiece,bring about the accurate measurement of cutting force is of great significance to push forward the research of metal-cutting theory and the realization of smart monitoring of numerical control machine tools in China.This paper point at the problem of poor measurement performance of traditional cutting force sensor in high speed cutting status,and its sensitivity and natural frequency can not be improved at the same time,a new pattem orthogonal decagonal ring three-dimensional cutting force sensor is developed.First of all,the orthogonal decagonal ring elastic sensing structure is proposed and designed,the simplified model of the force analysis of the decagonal ring is established,the stress expression of the inner and outer surface of the decagonal ring is deduced,based on this,the suitable position of the package strain gauge is determined,which lays the foundation for the later paste work of strain gauge.Secondly,the stress variation law of the special path of the ten angle ring model is simulated and verified by the finite element method,the relationship between the stress and strain distribution of orthogonal decagonal ring under the action of each cutting force is analyzed,the cutting force measuring circuit with strong anti cross interference capability is designed.According to the simulation results and the traditional octagonal ring design scheme,the orthogonal decagonal ring structure design significantly improves the sensitivity of the traditional octagonal ring cutting force sensor in each cutting force direction,and maintains a good dynamic performance.Again,the response surface multi-objective optimization method is used to optimize the elastic sensitive structure of the sensor.The maximum deformation of the decagonal ring elastomer increases by 6.6%compared with the traditional octagonal ring structure,The natural frequency of the main cutting force direction increases by 9.4%compared with the octagonal ring structure,according to the optimization results,the physical construction of the sensor is processed and the strain gauge is pasted.Finally,the performance test of the sensor has been carried out,the experiment results show that the static performances of the sensor is awesome,the response rate of the main cutting force,feed force and direction of resistance force is 0.049m V/N,0.052m V/N and0.011m V/N respectively,the linearity of each cutting force direction of the sensor is between0.1%and 0.5%,the repeatability is between 0.9%and 2.59%,the hysteresis is between 0.05%and 0.25%,and the cross interference between different cutting forces is between 0.2%and3.85%,the natural frequency of the sensor in F_cdirection is 1605Hz respectively,which can meet the measurement of cutting force under the condition of high speed cutting of the machine tool spindle speed not exceeding 24165r/min.The actual cutting test results show that the cutting force sensor can reflect the changes of cutting parameters online and sensitively,and has the potential to accurately measure the cutting force.