Accurate machining simulation requires high-quality experimental data acquired under realistic cutting conditions. Conventional piezoelectric dynamometers provide reliable force measurements but are limited in dynamic bandwidth. This study proposes an in-situ force measurement strategy based on strain gauges embedded directly within the tool-holder, combined with a fully synchronized high-frequency acquisition system. Two sensing technologies, piezoelectric (Worms Dragonfly®) and semiconductor gauges, are benchmarked against a reference dynamometer during orthogonal cutting of an aluminium alloy Al7075-T6 on an experimental demonstrator ARRIBRAVE. Static and motion calibration procedures are implemented to account for structural and inertial effects. Results show that embedded gauges deliver force-related signals consistent with dynamometer measurements while exhibiting enhanced dynamic sensitivity due to their reduced mass and proximity to the cutting zone.
Rossi et al. (Thu,) studied this question.