Abstract
Sensor-equipped cutting tools are becoming more common in the metal cutting industry as the demand for process monitoring and automation grows. These products are used for monitoring cutting forces and vibrations during machining with the objective of providing valuable insight into tool deflection, tool wear, surface finish, and process stability. The number of sensors and their position in the cutting tool, are often restricted by price and the thermo-mechanical loads acting in the cutting zone. Obtaining accurate measurements is a challenge due to mechanical filtering between the sensor positions and the tool tip as well as due to measurement noise from the sensors and electronics. This paper presents a method to estimate dynamic loads and tool tip vibrations using recorded data from strain sensors in a cutting tool. This is achieved through output-only calibration of an analytical model of the cutting tool, which defines the strain-force relationship based solely on the measured strain response data. This approach provides key parameters, including the first resonance frequency and the damping ratio of the cutting tool. The model is then applied to eliminate unwanted dynamic effects from the measured strain data, enhancing the accuracy of predictions of forces and tool tip displacement.
Keywords
Cutting force estimation, Deflection prediction, Metal cutting dynamics, Sensor-equipped cutting tools, Strainforce transfer function
Reference
Wu, P., Liljerehn, A., Magnevall, M., & Östling, D. (2025). Cutting Force Estimation in Sensor-Equipped Metal Cutting Tools Using Strain-Force Transfer Function. In Dynamic Substructuring & Transfer Path Analysis, Vol. 4 : Proceedings of the 43rd IMAC, a Conference and Exposition on Structural Dynamics 2025. River Publishers. Presented at International Modal Analysis Conference IMAC-XLIII, Orlando, Feb 10-13, 2025.
