This project has only recently come online and involves the novel application of strain measurement equipment on a broaching tool to indirectly assess the process forces. A broaching tool was digitised and modelled. The cutting process was simulated in software to assess where the optimal position for the strain equipment was. Based on the model and practical considerations strain sensors were strategically mounted to the tool.
The process was modelled in an Instron loading machine where work-piece samples were ran through the teeth of the broaching tool to simulate the actual cutting process.
Both wired and wireless strain data was captured from the system and compared to industry standard 3 axis cutting force dynamometer results. Work is ongoing and tests in a real industrial broaching machine will be carried out in the future.