Design and Fabrication of a Strain Gauge Type 3-axis Milling Tool Dynamometer

Pathri, Bhargav Prajwal; Garg, Ayush; Unune, Deepak Rajendra; Mali, Harlal Singh; Dhami, S. S.; Nagar, Ravindra

doi:10.4018/ijmfmp.2016070101

Cited by 7 publications

(8 citation statements)

References 12 publications

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“…Though the strain gauge cutting force sensing systems are capable of providing more accurate measurement, they have limitations like limited bandwidth, high cost, layout constraints, and fragility to overload [52,53,54,55]. …”

Section: Cutting Force Sensing Techniquesmentioning

confidence: 99%

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining

Liang

Zhang

et al. 2016

Sensors

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Multi-component cutting force sensing systems in manufacturing processes applied to cutting tools are gradually becoming the most significant monitoring indicator. Their signals have been extensively applied to evaluate the machinability of workpiece materials, predict cutter breakage, estimate cutting tool wear, control machine tool chatter, determine stable machining parameters, and improve surface finish. Robust and effective sensing systems with capability of monitoring the cutting force in machine operations in real time are crucial for realizing the full potential of cutting capabilities of computer numerically controlled (CNC) tools. The main objective of this paper is to present a brief review of the existing achievements in the field of multi-component cutting force sensing systems in modern manufacturing.

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Section: Cutting Force Sensing Techniquesmentioning

confidence: 99%

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining

Liang

Zhang

et al. 2016

Sensors

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“…Moreover, later, they developed an embedded multisensory system on the rotating dynamometer for real-time condition monitoring in milling [6]. Rathri et al [7] designed a strain gauge type 3-axis milling tool dynamometer, which contains four octagonal ring members bonded with strain gauges. Qin et al [8] developed a cutting force dynamometer for measuring axial force and torque in milling.…”

Section: Introductionmentioning

confidence: 99%

Development and Testing of a High-Frequency Dynamometer for High-Speed Milling Process

Lyu

Jamil

et al. 2021

Machines

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Cutting forces are strongly associated with the mechanics of the cutting process. Hence, machining forces measurements are very important to investigate the machining process, and numerous methods of cutting forces measurements have been applied. Nowadays, a dynamometer is the most popular tool for cutting forces measurements. However, the natural frequency of a dynamometer has a direct impact on the accuracy of measured cutting forces in the machining process. Therefore, few dynamometers are appropriate and reliable to measure the cutting forces at high frequencies. In this work, a new strain-gauge-based dynamometer (SGBD) with a special structure was designed, manufactured, and put to the test to ensure the measurement of high-frequency dynamic forces in the milling process. The main structure of the SGBD is symmetrical and mainly consists of a center quadrangular prism surrounded by four force sensing elastic elements, an upper support plate, and a lower support plate. The dynamic identification test was conducted and indicated that the SGBD′s natural frequency could be stabilized at a high value of 9.15 kHz. To automatically obtain the milling force data with a computer during high rotational speed milling, a data acquisition system was devised for the dynamometer. To reduce the effects of cross-sensitivity and acting point of force, an innovative model based on a conversion matrix was established for the dynamometer. Furthermore, the cutting tests were conducted at high rotational speeds (10,000–18,000 rpm), and it was found that the difference of cutting forces between the SGBD and a Kistler dynamometer are 2.3–5.8% in the X direction and 3.5–8.8% in the Y direction. The experimental findings disclosed that the new kind of dynamometer is reliably for the measurement of high-frequency dynamic forces in milling at high rotational speeds.

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“…Various researchers designed and fabricated the dynamometers with the strain gauge for measuring the cutting force during turning and milling process up to a maximum of 4500 N with a sensitivity of ± 5 N and a cross sensitivity error of less than 1 % [16][17][18][19][20][21][22][23][24][25]. The metrological characteristic of simple square ring shaped force transducer was studied analytically and computationally [26].…”

Section: Introductionmentioning

confidence: 99%

Design, development, calibration, and testing of indigenously developed strain gauge based dynamometer for cutting force measurement in the milling process

Mohanraj¹,

Shankar²,

Rathanasamy³

et al. 2020

JMES

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In this work, a milling dynamometer based on strain gauge with an octagonal and square ring was designed and tested. Strain gauges were attached with the mechanical rings to detect the deformation, during the machining process. Wheatstone bridge circuit was equipped with gauges to acquire the strain as voltage owing to the deformation of mechanical rings when machining takes place. The finite element analysis (FEA) was used to identify the location of maximum deformation and stress. The direction of rings and location of gauges were decided to increase the sensitivity and decrease the cross-sensitivity. Then, the cutting force was acquired through NI 6221 M series data acquisition (DAQ) card. The dynamometer had undergone a cycle of tests to verify its static and dynamic characteristics. The metrological characterization was performed according to the calibration procedure based on ISO 376 – 2011 standard. The cutting force was measured with both the dynamometers through milling experiments based on Taguchi’s L9 orthogonal array and the results were recorded. The measured cutting force varied from 300 N to 550 N. The obtained results depicted that low-cost milling dynamometer was reliable to measure the three component machining force. Overall, the square ring based dynamometer provides the better static and dynamic characteristics in terms of linearity, cross-sensitivity (4%), uncertainty (0.054%), and natural frequency (362.41 rev/s).

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Design and Fabrication of a Strain Gauge Type 3-axis Milling Tool Dynamometer

Cited by 7 publications

References 12 publications

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining

Development and Testing of a High-Frequency Dynamometer for High-Speed Milling Process

Design, development, calibration, and testing of indigenously developed strain gauge based dynamometer for cutting force measurement in the milling process

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