Professional Documents
Culture Documents
LM 10
LM 10
2
Mechanics of
Machining
Lesson
10 Dynamometers
for measuring
cutting forces
Instructional objectives
At the end of this lesson, the students would be able to
(1)
(2)
(3)
(4)
Physical variable
(cutting force, temp. etc.)
Conditioning stage (
Conditioned signal
Reading or recording
where,
(10.1)
3EI
L = overhang or equivalent projected length of the cantilever
type tool (holder)
E = physical property (Youngs modulus of elasticity of the
L
=P
beam)
I = size (plane moment of inertia) of the beam section. Since
for a given cutting tool and its holder, E and I are fixed and the equation
10.1 becomes,
PZ or, = kPZ
where, k is a constant of proportionality.
PZ
(10.2)
ri
(a)
(b)
PZ
d
fixed coil
(c)
moving core
(d)
Load, N
250
PZ 200
150
100
tan = k
50
*
0
4
6
Deflection, , mm
rement system (dial gauge)
F
i (2) Measuring cutting
force
by
g
monitoring elastic
.
strain caused by
1
the force.
0
Increasing
deflection,
.
4 enhances sensitivity of the
dynamometer but may
C affect machining accuracy
a where large value of is
the
cutting
l restricted,
forces
are
suitably
i
b measured by using the
r change in strain caused by
the force. Fig. 10.5 shows
a
the principle of force
t
measurement
by
i measuring strain, , which
o would be proportional with
n the magnitude of the force,
F (say PZ) as,
o
f
m
e where,
c
h
a
n
i
c
a
l
m
e
a
s
u
= M
8
surface from the
neutral plane of the
beam (tool)
PZ
L
T
Strain gauges
E
M = bending moment
Z = sectional modulus (I/y) of the tool section
I = plane moment of inertia of the plane section
y=
dis
Fig. 10.5 Measuring cutting
ta
forces by strain gauges
nc
e
of
th
e
str
ain
ing
B
M
d
i
a
g
r
a
m
V
e
r
s
i
o
n
2 ME IIT, Kharagpur
The strain, induced by the force changes the electrical resistance, R, of the
strain gauges which are firmly pasted on the surface of the tool-holding beam
as
R
= G
(10.5)
R
where,
G = gauge factor (around 2.0 for conductive gauges)
The change in resistance of the gauges connected in a wheatstone bridge
produces voltage output V, through a strain measuring bridge (SMB) as
indicated in Fig. 10.6.
Out of the four gauges, R 1, R2, R3 and R4, two are put in tension and two in
compression as shown in Fig. 10.6. The output voltage, V, depends upon the
constant, G and the summation of strains as,
GE
[1 (2 ) +3 (4 )]
V=
4
where, 1 and 2 are in tension and - 3 and - 4 are in
compression The gauge connections may be
1 full bridge (all 4 gauges alive) giving full sensitivity
2 half bridge (only 2 gauges alive) half sensitive
3 quarter bridge (only 1 gauge alive) th sensitivity
(10.6)
PZ
R1(T
)
R3(
)
R2(C)
R4(C
R1
for bal
R2
R4
R3
E
Fig. 10.6 Force measurement by strain gauge based transducer.
SMB
(3)
Piezoelectric
crystal
t
emf
Aluminium cover
tool
Tool
holder
dynamometer
shank
Strain gauges
Strain gauges
for thrust
Strain gauges
for torque
Job
gauges
for thrust
Fig. 10.12 A strain gauge type drilling dynamometer and its major
components.
1 Milling dynamometer
Since the cutting or loading point is not fixed w.r.t. the job and the
dynamometer, the job platform rests on four symmetrically located supports in
the form of four O-rings. The forces on each O-ring are monitored and
summed up correspondingly for getting the total magnitude of all the three
forces in X, Y and Z direction respectively.
Fig. 10.13 shows schematically the principle of using O-ring for measuring two
forces by mounting strain gauges, 4 for radial force and 4 for transverse force.
PZ
PX
X3 (C)
Z2 (T)
PY
X1 (T)
Z3 (C)
Z1 (T)
PX
Z4 (C)
X4 (C)
X2 (T)
(a) octagonal ring
1 Grinding dynamometer
The construction and application of a strain gauge type (extended O-ring)
grinding surface dynamometer and another piezoelectric type are typically
shown in Fig. 10.15 and Fig. 10.16 respectively.