In this paper, a smart cutting tool developed by the authors is presented to address the demand of smart adaptive machining, which can real-time monitor cutting forces in a plug-and-produce manner without additional equipment; easy to use and minimum modification of the cutting tool; employed at low cost and adequate accuracy and sensitivity. The smart cutting tool has integrated efficient sensors combination using piezoelectric films to directly measure the 3 dimensional cutting forces real-time in ultraprecision machining. Piezoelectric film sensors combination generates electrical signals under cutting forces acting at the nose tip of the diamond cutting tool. The four output electrical signals can be acquired, amplified, and processed with decoupling so as to measure 3 dimensional cutting forces with adequate accuracy.
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