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Materials and Design 27 (2006) 839846
www.elsevier.com/locate/matdes
Abstract
In this study, a turning dynamometer that can measure static and dynamic cutting forces by using strain gauge and piezo-electric
accelerometer, respectively, has been designed and developed. The orientation of octagonal rings and strain gauge locations has been
determined to maximize sensitivity and to minimize cross-sensitivity. The developed dynamometer is connected to a data acquisition
system. Cutting force signals were captured and transformed into numerical form and processed using a data acquisition system
consisting of necessary hardware and software running on MS-Windows based personal computer. The obtained results of machin-
ing tests performed at dierent cutting parameters showed that the dynamometer could be used reliably to measure cutting forces.
Although the dynamometer was developed primarily for turning operations, it can be used to measure cutting forces during nearly
all machining operations (milling, drilling, etc.).
2005 Elsevier Ltd. All rights reserved.
0261-3069/$ - see front matter 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2005.04.001
840 nsacar / Materials and Design 27 (2006) 839846
S. Yaldz, F. U
Ft
2. Materials and methods
Fc
2.1. Dynamometer
F
A three-force component analogue dynamometer
capable of measuring cutting forces during turning
was designed, developed and tested. A computer con-
nection for data acquisition was also made and Fig. 2. Cutting force components which occurs during metal cutting in
turning.
calibrated. The analogue data can be evaluated numer-
ically on a computer and when required can be con-
verted back to analogue. The schematic representation 3. Design and construction of a strain gauge based
of the cutting force measurement system is shown in dynamometer for lathe
Fig. 1.
The dynamometer is capable of measuring feed force 3.1. Design criterions and material of dynamometer
(Ff), thrust force (Ft) and main cutting force (Fc) which
occurs during turning operations as seen in Fig. 2. Sensitivity, rigidity, elasticity, accuracy, easy calibra-
This dynamometer consist of four elastic octagonal tion, cost and reliability in the harsh cutting environ-
rings on which strain gauges were mounted and neces- ment have been taken into account in designing the
sary connection were made to form measuring the dynamometer. Dimensions, shape and material of dyna-
Wheatstone bridges. mometer are considered to be eective factors on dy-
namic properties of the dynamometer.
2.2. Data acquisition A dynamometer essentially consists of an important
ring element. The rigidity, high natural frequency, cor-
On-line and real-time information of the cutting force rosion resistance and high heat conductivity factors
data are automatically read and stored by a system dur- were taken into consideration while selecting the ring
ing metal cutting. Since the output from Wheatstone materials. Also, deformation under the load should con-
bridge circuits is very low due to the high stiness form to that of strain gauges [2].
requirement of the dynamometer, the analogue signals In this study, AISI 4140 steel, which meets above
coming from dynamometer amplied by strain gauge in- requirements, was selected as the ring material. The
put modules (Advantech ADAM 3016) are then con- properties of this material are given in Table 1.
verted to digital signals and captured by PCL-818H
data acquisition card installed in MS-Windows based 3.2. Determination of dimensions of the octagonal rings
PC. The stored data can be retrieved and used for anal-
ysis when required. The data acquisition software is The thickness t, radius r, and width of the circular
capable of averaging and graphical simulation of force strain ring b are the three basic controllable parameters
signals in process. that aect the rigidity and sensitivity. Since there is no
The dynamometer is considered to be a small mass The thrust force Ft are supported by A, B, C and D
supported by ring elements for analytical purpose. In or- rings of the dynamometer as shown in Fig. 5. The strain
der to determine the natural frequency of the dynamom- gauges 3, 4, 7, 8, 11, 12, 15 and 16 are aected by the
eter, the ring constant of dynamometer should be thrust force Ft. Among these strain gauges, 3, 7, 11
determined rst. The stiness value for a thin circular and 15 are subject to tensile stress while 4, 8, 12 and
ring is given as in the following equation [8]: 16 are subject to compressive stress.
The feed force Ff is supported by A and C rings of the
Ft Ebt3 dynamometer as shown in Fig. 5. The strain gauges to
Kt . 6
dt 1.8r3 measure the feed force Ff should be mounted on the out-
As placing the related values in Eq. (6), the ring constant er surfaces of A and C rings with 45 inclination angle.
of the dynamometer is computed as; Kt = 36,458 N/mm. As shown in Fig. 5, the strain gauges 1, 2, 5 and 6 are
The natural frequency of dynamometer, which is as- aected by the feed force Ff. Among these strain gauges,
sumed to be a small mass supported by ring elements, 1 and 5 are subject to tensile stress while 2 and 6 are sub-
can be obtained from the following relation [8]: ject to compressive stress.
The main cutting force Fc is supported by B and D
1 p rings as seen in Fig. 5. The strain gauges for measuring
fd K=m; 7
2p the main cutting force Fc are mounted on rings B and D
where K is the dynamometer ring constant (N/mm), m with 45 inclination angle with respect to the vertical
the dynamometer mass (kg), fd the dynamometer natu- plane. As shown in Fig. 5, the strain gauges 9, 10, 13
ral frequency (rev/s). and 14 are aected by the main cutting force Fc.
The ring mass is 36.43 kg. As placing the related val-
ues in Eq. (7), the natural frequency of dynamometer is 3.6. Setting the Wheatstone bridges used in the
computed as fd = 159.2 rev/s. To full the requirement dynamometer
as stated above fd > 4fm, the maximum spindle speed
of the lathe should be 200 rev/s or 12,000 rpm. One full eight active arms bridge arrangement can be
arranged for thrust force measurement and two full four
3.5. The orientation of the strain gauges and the rings on active arms bridge can be arranged for feed force and
the dynamometer main cutting force. Thus, if four active arms are used
in one bridge, the bridge output becomes four times
The proper selection of the points where the strain greater than the single arm bridge. Also, full bridge cir-
gauges are mounted is essential for achieving high accu- cuit is fully compensated for any change in resistance
racy in the Wheatstone bridge circuits. The orientation due to the temperature.
of the strain gauges on the rings and the position of The strain gauges used have 5% elongation limit on a
the rings on the dynamometer are given in Fig. 5. 6 mm. length. So the maximum allowed elongation
12 5 6 9 10 13 14
3 4 8 7 11 12
A C B D 16 15
W Strain guages
C
B Y
Ff
L
X
A Fc D
L
W
should be less than 6 5% = 0.3 mm. The possible elon- relation is obtained. Or, this relation can be rearranged
gation could occur by 3500 N maximum permissible as
force (F) on a dynamometer and it has 36,458 N/mm
UA 4UE 106 . 17
rigidity (K) can be calculated as follows:
The principles applied to the thrust force Ft are also va-
K t F t =dt ;
8 lid for the feed force Ff. By using the principles of thrust
dt F t =K t 0.096 mm. force Ft, the feed force Ff equation can be formed.
Thus, the obtained possible elongation value 0.096 mm Again, from Eq. (12)
is lower than 0.3 mm allowable elongation limits. UA 2eUE
The strain occurring in the strain gauges can be stated
or can also be written as
by the following relation [7,11]:
DR DL UA 2UE 106 . 18
k ; 9
R L0 Similarly, the principles applied for feed force Ff and
where DR is the dierential resistance due to the voltage thrust force Ft are also valid for the main cutting force
(X), R the resistance of the strain gauge prior to applica- Fc. See Fig. 6.
tion to voltage (X), K the gauge factor (ratio) of strain
gauge, DL the elongation due to the stress (mm), and 3.7. Dynamometer construction
L0 the initial length (mm).
Elongation percent of the strain gauge is stated by 3.7.1. Mounting of strain gauges on the rings
DL/L0 = e. Therefore, the above formula can be rewrit- The rings of dynamometer were manufactured at
ten as DR/R = ke. The bridge unbalance V is the ratio of CNC machine tools by using AISI 4140 steel as seen
output voltage UA to input voltage UE of the bridge in Fig. 7. The surfaces of the rings were ground for bet-
circuit is given by the following relation [1114]: ter strain gauge application.
Prior to the mounting of the strain gauges, the ring
UA 1 DR1 DR2 DR3 DR4 surfaces on which strain gauges were mounted had been
V . 10
UE 4 R1 R2 R3 R4 ground and then these surfaces were cleaned by cleaning
If R1 = R2 and R3 = R4 the bridge is balanced or, in the set HBM: FC1. Around 30 min after the cleaning of
other words, the bridge unbalance is zero. Substituting
DR/R =keV is found as
UA 1
V ke1 e2 e3 e4 ; 11
UE 4
where as e1 = e2 = e3 = e4 = e/UA/UE = (1/4)(k
4e) and strain gauge ratio factor is taken k = 2, the output
voltage can be reduced to the following denition:
UA 2eUE. 12
If the Eq. (12) giving the output voltage of Wheatstone
bridge circuit is applied to thrust force Ft, bridge
Fig. 6. Wheatstone bridge connections (a) for Ff, (b) for Ft and (c) for
circuit Fc.
UA 1 DR3 DR11 DR4 DR12
k
UE 4 R3 R11 R4 R12
A M6
DR7 DR15 DR8 DR16
13
R7 R15 R8 R16
is obtained.
As
32
40
UA 1
ke3 e11 e4 e12
UE 4 5 10
e7 e15 e8 e16 ; 14
e3 e11 e4 e12 e7 e15 e8 e16 e 15 3
A
for UA/UE = (1/4)(k 8e) and k = 2 Section A-A
UA 4eUE 16 Fig. 7. Manufactured octagonal dynamometer rings.
844 nsacar / Materials and Design 27 (2006) 839846
S. Yaldz, F. U
the surfaces, the strain gauges were mounted using cold plates were covered with 5 mm thick transparent plastic
curing rapid adhesive HBM: Z70 and were left for material in order to prevent the strain gauges from hot
drying for 10 min. After curing time, the surfaces of chips and from cutting uid during turning.
the strain gauges were covered by nitrile rubber HBM: The dynamometer was xed on to the saddle of lathe
NG150 to protect against the inuence of cutting uid. in a position where the nose of the cutter tips was on the
Totally 16, strain gauges were mounted on four same line with chuck centre.
octagonal rings. Two strain gauges were mounted hori-
zontally on to outsides of each ring at 45 angles. Two 3.8. Dynamometer calibration
more strain gauges, one inside and the other outside
were also mounted vertically. See Fig. 5. 3.8.1. Static calibration of the dynamometer
HBM: LY11 6/120 type strain gauges recommended In order to determine the elastic deection of ring
for steel specimens and for static or dynamic loading components and consequently the output voltage under
were utilised. To achieve low energy dissipation and static load, the dynamometer was calibrated. The cali-
hence a stable zero setting for a long time, excitation bration was made in three directions for Ff, Ft, Fc and
voltage must be selected carefully. The range of excita- the output voltages of millivolt were averaged for each
tion voltage for a thick steel mounting surface may be direction. The loads up to 2000 N 50 N intervals were
obtained from the relation [15] applied and the strain values were recorded for each
q load intervals. Thus, calibration curves were obtained
V in 2 RP 0g Ag to convert the output readings into cutting force values.
Figs. 911 show the calibration curves for feed force,
in which R is the gauge resistance in ohms, P 0g is the
thrust force and main cutting force, respectively. In or-
power density in the gauge grid (between 2 and 5 kW/
der to verify the consistency, the measurements were re-
m2), and Ag is the active grid area (6 2.8 for HBM
peated three times and very close values were obtained
for LY11 6/120). For convenience, an excitation voltage
as seen in Figs. 911. The eect of loading in one direc-
of 10 V (calculated between 8 and 12.7 V) was
tion on the other force components was also examined
employed.
and minor uctuations were observed. These eects were
3.7.2. Mounting of the dynamometer
The rings of dynamometer were mounted between
two plates by using (B4 mm) pins and M5 screws. Pins
were used in order to prevent the motion of plates due to
clearance, which may cause the cross-sensitivity during
measurements. The dimensions of plates were
100 100 12 mm. The cutter was placed tightly into
the hole of the front plate and tightened with M8 screws
to upper plate in order to sustain the perpendicularity to
the ring plane (see Fig. 8). The sides of front and rear
Fig. 8. Designed and developed dynamometer. Fig. 10. Calibration curve and cross-sensitivity for thrust force Ft.
nsacar / Materials and Design 27 (2006) 839846
S. Yaldz, F. U 845
Fig. 12. Dynamic cutting force within the time domain and frequency domain.
846 nsacar / Materials and Design 27 (2006) 839846
S. Yaldz, F. U
Table 2
The results of tests performed on the dynamometer
Axes Load (N) Output e (digital) Average error (%)
X Y Z X Y Z
The results of cross-sensitivity test
Ff 2000 278 5 2 0.18 0.7
Ft 2000 8 239 1.3 0.33 0.5
Fc 2000 16 3 173 0.92 0.17
give same output value. To test this condition, the dyna- References
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