What question did this study set out to answer?

To develop a new strategy for measuring cutting forces in machining processes using embedded strain gauges.

June 12, 2026Open Access

A Novel In-Situ Measurement Strategy for Orthogonal Cutting Forces

Key Points

To develop a new strategy for measuring cutting forces in machining processes using embedded strain gauges.
Developed a measurement system using embedded strain gauges in a tool-holder.
Compared performance of piezoelectric and semiconductor gauges against a reference dynamometer.
Implemented calibration procedures to account for structural and inertial effects.
Embedded gauges provided consistent force measurements with dynamic sensitivity, outperforming traditional methods.
Showed better performance due to reduced mass and proximity to the cutting zone.

Abstract

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.

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