Performance of a new piezoceramic thick film sensor for measurement and control of cutting forces during milling

For improving the performance of milling processes, process monitoring and controlling with detailed real-time information such as the cutting force is required. This paper presents a novel system for measuring the cutting force in the direct vicinity of the indexable insert. The outlined concept makes use of thin piezoelectric sensor layers mounted directly below the insert. The unique design and features of the new sensor enable accurate and continuous force measurements as well as the indication of wear and tool life. The results of the experimental investigations are presented and compared to results of a conventional dynamometer.