Cutting force measurement has become a crucial activity for enhancing machining process performance. This paper described the design and fabrication of embedded Ni-chrome thin-film micro-sensors in tool holders to measure the cutting force in machining operations. A Ni-chrome thin-film sensor device is embedded within a substrate structure through a dy- namic brazing process, which consists of a Ti6A14V substrate, a nickel-chromium thin-film sensor and an alumina insulating layer. The Wheatstone bridge which consists of four sensors would produce the output voltage when the thin film caused de- formation by the cutting forces. The relationship between input and output voltages was theoretically analyzed. According- ly, an in-process cutting force measurement system is established. The results show that the thin-film sensor had good lineari- ty and less mutual interference, and it is suitable for all kinds of turning forces under the measurement conditions.
