In turning processes, cutting force is of great importance since many cutting force features are useful for predicting and detecting tool conditions. To precisely measure cutting forces, many commercial devices have been developed; however, they are costly, cumbersome, and some implementation restrictions could hinder their suitability in real applications. In this work, a simple, portable, and low-cost tool holder sensor was designed and developed to sense strain and measure cutting force applied during ultra-precision diamond turning. The device can assess cutting intensity up to 3 N with a high sensitivity of 4.592 mV/N or 0.004592 V/N, a calibration test variability of 99.6%, and a percentage error of 2.19, according to static calibration testing.
cutting force, force sensor, in-process metrology, single-point diamond turning, strain gauge
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