Real-time Detection Of Three-component Micro Cutting Force In The Micro Turning-milling-compound Machining

With the increasing demand for precision micro systems in the fields of aviation, aerospace, military, and medical, significant attention has given to the manufacturing technology of three-dimensional precision micro components with part size features between 0.1 and 10 mm and machining size features between 0.01 and 1 mm. However, traditional machining technology can not meet the requirements because of its relatively low accuracy. Similarly, as a traditional manufacturing technology of micro-electromechanical systems, lithography-based fabrication processes have limitations when applied to these new micro devices which require the use of a variety of materials and complex three-dimensional microstructures with high aspect ratios. As a supplementation of silicon micromachining technology, precision micro machining technology which takes the micro turning-milling-compound machining technology as representative, has already become an important machining support to non-silicon complex three-dimensional microstructures which have complicated curved surfaces an special-shaped features. However, the research of the turning-milling-componend machining technology is still in the initial stage compared to the traditional turning and milling technology. At present, the research on the machining process of the turning-milling is limited on the machining mechanism, and there are few studieds on the cutting parameters and the cutting process of different materials. Precision measurement for cutting force plays an important role in the machining accuracy, roughness, efficiency, and processing stability of the turning-milling-compound machining, and it is also the most important approach to achieve feedback control, tool design, tool condition monitoring, optimization of cutting parameters, optimization of cutting process, and machinability testing. Therefore, it is of great significance for improve the machining precision and study the machining process to build the wireless cutting force measurement system in the turning-milling-compound machining, and to improve the machining precision and study the machining process.The cutting force measuring system in turning-milling-compound machining is studied in this paper. The main contents include overall measurement plan scheme setting, cutting force measuring sensor and measuring device design, circuit and program design and calibration experiment and experimental verification. A new design scheme of “direct measurement, wireless transmission” is proposed to measure the three-component micro cutting force in turning-milling-compound machining process. A three-componnent force sensor and its overall measuring device are designed. The matching program and software are designed including the amplifier circuit, filter circuit, data acquisition circuit, data transmission and data processing of force sensor signal. The force sensor and the measuring device are calibrated with high precision weight, and the relationship between the force and output signal of the three-component force sensor is established. Finally, actual machining experiments with different cutting parameters are adopted, and the results are compared with the theoretical values, and the feasibility of the measurement system is verified.