Real-time cutting force measurement is significantly important to monitor tool condition and machining process. Although commercial dynamometers are available for a range of machining applications, there is a lack of multipoint and low-cost measuring methods suitable for detecting cutting forces in harsh machining environments. In this paper, a smart cutting tool integrated with optical fiber sensors is first presented for cutting force measurements in turning. Fiber Bragg grating (FBG) sensors are employed to acquire cutting force information on cutting tools. Compared with the electrical and piezoelectric sensors, the proposed smart cutting tool has unique advantages such as electromagnetic interference immunity, explosion proof, ability to measure multiple cutting forces in the same and simplified data acquisition device with along-distance signal transmission, and enabling it to work in harsh machining environments. In addition, the proposed smart tool brings little effect on the structure and characteristics of machine tools due to FBGs’ small size and light weight. This paper investigates the operating principle of the sensory cutting tool theoretically and validates it using finite-element simulations. A prototype of the proposed device was developed and tested. Static calibration, dynamic identification experiment, and comparative cutting tests were conducted to evaluate its performances. The experimental results have shown that the cutting forces acquired by the developed smart tool are in good agreements with the results obtained by the reference commercial dynamometer. The proposed smart cutting tool has the potential to provide a new solution to the real-time measurement and monitoring of multipoint cutting forces in turning processes.

中文翻译：

---

集成光纤传感器的智能刀具，用于车削切削力测量

实时切削力测量对于监控刀具状况和加工过程非常重要。尽管商用测功机可用于一系列加工应用，但缺乏适合在恶劣加工环境中检测切削力的多点和低成本测量方法。在本文中，首次提出了一种集成光纤传感器的智能切削刀具，用于车削切削力测量。光纤布拉格光栅 (FBG) 传感器用于获取刀具的切削力信息。与电传感器和压电传感器相比，所提出的智能刀具具有独特的优势，如抗电磁干扰、防爆、能够在同一个简化的数据采集设备中测量多个切削力，并具有远距离信号传输，使其能够在恶劣的加工环境中工作。此外，由于FBG的体积小、重量轻，所提出的智能刀具对机床的结构和特性几乎没有影响。本文从理论上研究了传感切削刀具的工作原理，并使用有限元模拟对其进行了验证。开发并测试了所提议设备的原型。对其性能进行了静态标定、动态识别实验和对比切削试验。实验结果表明，开发的智能工具获得的切削力与参考商用测功机获得的结果非常吻合。所提出的智能切削刀具有可能为车削过程中多点切削力的实时测量和监测提供新的解决方案。