Structural Design And Optimum Analysis Of Thin Film Sensor For Cutting Force Measurement

In the process of cutting,accurate measurement of cutting force is of great significance for studying the cutting mechanism and improving the processing quality.In order to improve the accuracy of cutting force measurement results,this paper studies the thin film sensor in the variable cutting force measurement system,and designs and optimizes the structure of the elastic substrate and strain grid in the thin film sensor.By increasing the strain of the elastic base structure under the same load,the strain transmission error between the film layers of the film sensor is reduced,and the accuracy and sensitivity of the cutting force measurement are improved.The main research contents of the thesis are as follows:(1)The relationship between strain and deflection of the elastic substrate of the thin film sensor is analyzed,and the relationship between the structural parameters of the elastic base and the deflection is derived.According to the theoretical formula deduced,elastic bases with different structural shapes are designed.The deflections of the substrates with different structural shapes under the same load were compared,and the structure with the largest deflection was selected,and the dimensional parameters of the structure were optimized.The results of design and optimization were verified using ABAQUS finite element analysis software.(2)Based on the analysis of the structural principle of the thin film sensor,the grid structure of the thin film sensor is designed.According to the structure of the designed sensor,the strain transfer analysis model of the thin film sensor is established.According to the force transmission principle,the strain transfer function between the sensor elastic substrate and the strain grid film is derived.Through the derived strain transfer function,the influence of the grid thickness,grid length and grid width variation of the strain grid on the variable transfer error is calculated.The calculation results were verified by finite element simulation analysis software.According to the theoretical calculation and the conclusion of the simulation analysis,the structural parameters of the strain grid are optimized.A set of better structural parameters that meet the design requirements of the strain grid are finally determined: grid thickness 0.001 mm,grid width 0.2mm,grid length 5.6mm.(3)The preparation process of each layer of film sensor was explored,and the preparation process of electrode layer film was optimized.After the preparation of the thin film sensor was completed,relevant experiments were designed using the prepared thin film sensor,and the results of sensor structure optimization were verified.