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<p>The accurate acquisition of cutting force is fundamental for understanding cutting mechanisms, optimizing tool design, and improving cutting processes. It also serves as a key data source for monitoring and controlling the cutting process. However, traditional measurement methods such as dynamometers and rotary force sensors have limitations, including complex installation and high costs, which restrict their application mainly to laboratory environments and make them less suitable for industrial settings. To tackle this challenge, this study proposes a novel smart tool holder (STH) solution that innovatively integrates a force/torque sensing unit, a data acquisition module, and a wireless transmission system, enabling real-time monitoring of six-axis force/torque. In the design of the sensing unit, a cross-beam structure is employed as the core elastic element, with high-precision silicon strain gauges strategically placed on its four measuring arms to ensure measurement accuracy. Through structural optimization, the design maximizes detection sensitivity while preserving the required stiffness of the tool holder, achieving an optimal balance between rigidity and sensitivity. Static calibration and decoupling results demonstrate that the STH exhibits high sensitivity (greater than 0.021&#xa0;mV/N), low measurement error (less than 0.57%), and minimal cross-interference error (below 6.41%). These characteristics enable precise measurement of multidimensional cutting forces in milling and drilling processes, providing a reliable measurement solution for industrial applications.</p>

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An integrated smart tool holder with six-axis cutting force sensors for milling and drilling operations

  • 期刊论文

  • 发表日期：

    2025年6月28日

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  • Pengfei Zhang,
  • Chao Sun,
  • Ang Li,
  • Qinghe Guan,
  • Liming Shu

摘要

The accurate acquisition of cutting force is fundamental for understanding cutting mechanisms, optimizing tool design, and improving cutting processes. It also serves as a key data source for monitoring and controlling the cutting process. However, traditional measurement methods such as dynamometers and rotary force sensors have limitations, including complex installation and high costs, which restrict their application mainly to laboratory environments and make them less suitable for industrial settings. To tackle this challenge, this study proposes a novel smart tool holder (STH) solution that innovatively integrates a force/torque sensing unit, a data acquisition module, and a wireless transmission system, enabling real-time monitoring of six-axis force/torque. In the design of the sensing unit, a cross-beam structure is employed as the core elastic element, with high-precision silicon strain gauges strategically placed on its four measuring arms to ensure measurement accuracy. Through structural optimization, the design maximizes detection sensitivity while preserving the required stiffness of the tool holder, achieving an optimal balance between rigidity and sensitivity. Static calibration and decoupling results demonstrate that the STH exhibits high sensitivity (greater than 0.021 mV/N), low measurement error (less than 0.57%), and minimal cross-interference error (below 6.41%). These characteristics enable precise measurement of multidimensional cutting forces in milling and drilling processes, providing a reliable measurement solution for industrial applications.