A robust embedded load cell sensor for tool life prognosis and smart sawing of medium carbon steel

An embedded load cell sensor is proposed for the tool life prognosis and thrust force control of a band saw machine. The sensor enables the tool life and surface quality of the machined workpiece to be effectively improved through the use of a single sensing device strategically located in the cutting machine. The feasibility of the proposed sensor is demonstrated experimentally using a double-column horizontal sawing machine with medium carbon steel bars as the workpiece material. An investigation is performed into the effects of the cutting force, feed rate, and machining time on the tool wear and surface roughness of the machined workpiece. It is shown that the thrust force, tool wear and surface roughness of the machined workpiece are strongly correlated and increase over time. Based on the experimental results, a feedback control system is proposed for maintaining a constant thrust force on the band saw during cutting under even the most challenging conditions. Overall, the results confirm that the embedded load cell sensor and force monitoring and control methodology proposed in the present study provide an effective approach for maintaining the optimal cutting conditions in the sawing of medium carbon steel and improving the tool life and machined part quality.