Design of a smart turning tool with application to in-process cutting force measurement in ultraprecision and micro cutting

In modern micromachining, there is a need to measure and monitor certain machining process parameters in process so as to detect tool wear in real time, to optimize the process parameters setup, and to render the machining process some level of smartness and intelligence. This paper presents the innovative design of a smart turning tool using two pieces of piezoelectric films to measure cutting and feed force in real time. The tool was tested on its performance through the calibration and cutting trials against the commercial dynamometer. The results show the smart turning tool has achieved the performance as designed.