Services Wireless Strain Measurement in CNC Turning
A Novel Demonstration of Low-Cost, Passive Sensor Technology in Live Machining
Effective process monitoring in CNC machining improves product quality, reduces material waste, and enhances resource efficiency. To achieve smarter, adaptive machine tools, robust and scalable sensing technologies must be applied directly to the machining environment. However, high-end sensor systems are often confined to R&D settings due to their cost and complexity, limiting their practical use on production floors.
This project explores an entirely novel approach using passive wireless strain sensors based on Surface Acoustic Wave (SAW) technology. These sensors were integrated into standard tool holders and tested on an OKUMA LT15M CNC turning centre. SAW sensors require no onboard power, enabling a compact and cost-effective solution for monitoring machining forces in real time.
Key Project Highlights
Tool Instrumentation … SAW strain sensors were embedded into tool holders without altering their structural performance. These passive sensors can detect force-induced strain wirelessly.
Lab Calibration and Validation … Prior to live machining, the system was validated using an Instron materials testing machine. Predefined loads were applied, and the strain readings were collected for full ISO-style calibration.
Live Machining and Comparison Testing … The sensor-equipped holders were tested both in simulation and under real cutting conditions. Throughout, they were mounted within a 3-axis force dynamometer to compare SAW data with conventional force measurements.
World-First Results … This study represents the first known application of SAW sensors to extract real-time CNC process force data directly from a turning tool in operation.
This demonstration proves the feasibility of low-cost, wireless, and passive sensor integration in industrial machining environments. It marks a major step toward scalable smart manufacturing.
Wireless Passive Force Measurement in Live CNC Turning
Following successful calibration, the wireless passive sensor system was deployed inside the OKUMA LT15M CNC turning centre for live testing in a real machining environment.
During the turning process, the SAW-based wireless strain sensors captured force-related data directly from the toolholder. This allowed real-time monitoring of cutting forces without any physical wiring or external power supply. Data was collected continuously across all sensors, confirming that the system could reliably sample and transmit accurate force signals during active CNC cutting operations.
This successful in-machine demonstration validates the potential of wireless passive sensor technology for scalable, non-intrusive process monitoring in modern CNC environments.
Sample Results
Below is a representative data set from the wireless strain monitoring system, with the SAW sensor output plotted alongside industry-standard force measurements for direct comparison. The results clearly demonstrate that the passive wireless SAW sensors track force trends with strong correlation, validating their performance against traditional wired systems.
This project marks the first known application of SAW technology in a live CNC machining environment, highlighting its potential as a scalable, low-cost solution for real-time process monitoring. Ongoing work aims to further develop and optimise this sensing method to meet growing industrial demand.
If you would like to learn more or discuss how this technology could support your application, please contact us.
Advanced Wireless Strain Measurement for CNC Turning
Our wireless strain measurement system is specifically designed for CNC turning applications where real-time monitoring is essential. Using precision sensors embedded directly into the cutting setup, we measure tool deflection and material deformation under various load and cutting conditions, enabling deeper insights into the process and enhanced control.
This high-speed system transmits data using robust wireless technology, eliminating the need for slip rings or wired transmission systems. Data can be collected across a broad range of cutting parameters and machining speeds, including complex transmission cycles and metal removal operations.
Whether you're focused on part design, thermal behaviour, or force distribution, our system delivers accurate temperature, strain, and vibration measurements for every cycle. Each measurement is timestamped and synchronised, providing consistent results across varying toolpaths and materials.
This service is ideal for research, prototyping, and production applications where understanding real-time energy and mechanical feedback is essential. We offer complete integration, support, and custom product development if required.
