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Testing of force sensors for the active measurement and limitation of axial loads in heavy turning

Kasprzak Marcin, Pyzalski Michal

Journal of Machine Engineering

2021

Vol. 21, No. 4

106--117

This article describes the design and construction of a feed drive load measuring system based on industrial strain gauges installed in the machine tool structure. The system was calibrated and dynamically tested in the range of 15 kN in real machining conditions. The tests showed that the system installed on a machine tool works correctly and its error amounts to about 5% of the measured range. Thanks to this measuring system the accuracy of the machine tool in machining conditions can be increased through the active compensation of the axial error caused by displacements. Moreover, the system can prevent tool breakage and increase machining efficiency.

Approach to feed drive load measurements in heavy turning

Medyk Pawel, Kasprzak Marcin

Journal of Machine Engineering

2020

Vol. 20, No. 4

41--58

It is well known that the forces loading the feed axes carry a lot of information about the machining process. The measurement of the forces opens the possibility of implementing such functions as cutting tool condition diagnosis, tool breakage detection and adaptive feed control aimed at maintaining constant loading. Hence inexpensive, but usable in industrial conditions, force sensors are sought for the steerable axes. The article describes a feed drive load measuring system based on industrial force sensors. These are strain gauge sensors located in the ball screw area. The system was designed for compressive and tensile forces of up to 30 kN. The effect of nonaxial forces on the measurement error is examined. The proposed system does not introduce any new elements into the machine structure and requires only its minor modifications. The system was tested in a strength testing machine.