Three-dimensional turning force sensor based on a decagonal ring structure: crosstalk mitigation design and performance optimization

Abstract Real-time data acquisition using high-precision three-dimensional turning force sensors is crucial for intelligent manufacturing. However, existing sensors face challenges such as low integration levels and poor crosstalk resistance, rendering them inadequate for high-precision measurements. Theoretical analysis has demonstrated that a fully centered decagonal ring structure can effectively mitigate the effects of eccentric loading. This study focuses on designing a fully centered turning force sensor with minimal crosstalk. To achieve a balance between sensitivity and stiffness, multi-objective optimization was conducted using GWO-BP and TOP algorithms, resulting in a twofold increase in the sensitivity of the decagonal ring. The sensor design incorporates metallic strain gauges, instrumentation amplifiers, and peripheral circuits into the ring arms of the decagonal structure. Experimental results show that the sensor’s amplified sensitivities in the F c, F f, and F p directions are 11.78 mV N −1 , 10.31 mV N −1 , and 1.78 mV N −1 , respectively. The first three natural frequencies in an unconstrained state are 2518.5 Hz, 2537.5 Hz, and 4256.4 Hz. The sensor’s F c- F y crosstalk ranges from 0.18% to 0.88%, with noise limits for the F c, F f, and F p directions of 0.035 N, 0.03 N, and 0.23 N, respectively. Cutting experiments have demonstrated that under varying spindle speeds and cutting depths, the sensor effectively detects surges in cutting force caused by rapid tool retraction, as well as other common faults.