Cutting Forces Assessment in CNC Machining Processes: A Critical Review

Abstract

Machining processes remain an unavoidable technique in the production of high-precision parts. Tool behavior is of the utmost importance in machining productivity and costs. Tool performance can be assessed by the roughness left on the machined surfaces, as well as of the forces developed during the process. There are various techniques to determine these cutting forces, such as cutting force prediction or measurement, using dynamometers and other sensor systems. This technique has often been used by numerous researchers in this area. This paper aims to give a review of the different techniques and devices for measuring the forces developed for machining processes, allowing a quick perception of the advantages and limitations of each technique, through the literature research carried out, using recently published works.

Keywords: CNC machining; cutting force measurement; cutting force prediction; cutting forces; dynamometer; finite element analysis; force sensor; process optimization; robotic machining.

Figure 1

Hybrid approach on machine-learning architecture [51].

Figure 2

Experimental procedure for the measure and comparison of cutting forces during machining [53].

Figure 3

(a) Real image with the position of the five accelerometers and one non-contact displacement transducer (NCDT) indicated in the machine’s spindle. (b) Scheme of the spindle (divided into two substructures) with 8 positions indicated for the calculation of the Frequency Response Function [55].

Figure 4

A prototype integrated with jaws embedded in strain gauges and piezoelectric sensors [65].

Figure 5

Temperature distribution on the tool–workpiece interface (a), workpiece (b), and tool (c) [76].

Figure 6

Scheme of the methodology adopted for the prediction and optimization of cutting forces [89].