Bridging Cost and Performance in Cutting Force Measurement: A PVDF-Based Universal Plate Dynamometer

Cutting force measurement plays a fundamental role in machining research and industrial applications, but existing dynamometers present important trade-offs between cost, stiffness, and dynamic bandwidth. Strain gauge devices are inexpensive but too flexible for high-speed operations, whereas piezoelectric systems provide excellent accuracy and bandwidth at prohibitive costs. This work presents the design, construction, and validation of a novel plate dynamometer based on polyvinylidene fluoride (PVDF) sensors, aimed at providing an effective alternative having an intermediate cost and suitable for advanced milling applications. The device integrates eight symmetrically arranged PVDF films in a stiff steel structure, complemented by four accelerometers for inertial compensation. A finite-element analysis confirmed favorable stress distribution at the PVDF contact surfaces and high resonance frequencies (under ideal clamping conditions). Modal tests demonstrated that uncompensated PVDF signals offer limited bandwidth, but the application of the Universal Inverse Filter (UIF) extended the usable bandwidth to 5 kHz along direct directions and up to 0.3–4 kHz along cross directions, approaching the performance of piezoelectric reference devices. Milling tests under diverse cutting conditions further validated the new device. Overall, the proposed device bridges the gap between low-cost strain gauge and high-performance piezoelectric dynamometers, offering a versatile and promising solution for both laboratory research and industrial applications.