Design and Analysis of Constantan Thin Films Sensor for Monitoring Cutting Force

Cutting force is one of important parameters for manufacturing processes. The traditional dynamometer is limited by size, machining environments, and so on. This paper introduces a new constantan thin film sensor which embedded on the holder of external turning tool to measure cutting force. The relationship between force and output voltage are deduced from theory. By using the finite element software, the analyses on induction and linearity capability of thin film sensor are simulated, and the influences of the location and thickness of film on the output voltage are analyzed. The results show that the linearity of input and output is good and the deviation between the calculated value and simulation results is identical. As the result, the constantan thin film sensor unit can be used to measure the cutting forces.