Development and testing of an integrated smart tool holder for four-component cutting force measurement

Cutting force measurement is a significant requirement for monitoring and controlling the machining processes. Hence, various methods of measuring the cutting force have been proposed by many researchers. In this study, an innovative integrated smart tool holder system based on capacitive sensors is designed, constructed and tested, which is capable of measuring triaxial cutting force and a torque simultaneously in a wireless environment system. A standard commercial tool holder is modified to make itself be the force sensing element that has advantages of simple structure and easy machining. Deformable beams are created in the tool holder, and the tiny deformations of which used to calculate the four-component cutting force are detected by six high precision capacitive sensors. All the sensors and other electronics, like data acquisition and transmitting unit, and wireless power unit, are incorporated into the tool holder as a whole system. The device is intended to be used in a rotating spindle such as in milling and drilling processes. Eventually, the static and dynamic characteristics of the smart tool holder have been determined by a series of tests. Cutting tests have also been carried out and the results show it is stable and practical to measure the cutting force in milling and drilling processes.