Faculty of Engineering

Mechanical Engineering Dept. 3rd Year production engineering.

M 1371 theory of metal cutting
Benha
Instructor: Dr. Ashraf Hassan Laboratory
University
experiments.

Experiment No(2)

CALIBRATION OF A TWO-COMPONENT CUTTING – FORCE DYNAMOMETER

11.2.1 Introduction

The cutting-force dynamometer is one of the most useful tools in experimental

work in metal cutting. It allows investigations of the effects of changes in cutting
conditions on the forces in the machining of various materials.
From the measurements of these effects certain parameters of interest such as the
mean coefficient of friction on the tool rake face, the effective, mean shear strength of
the work material during machining, and the power consumption can be determined.
For orthogonal machining the dynamometer is required to measure the cutting force
Fc and the thrust force Ft, which are the components of the resultant tool force
parallel and normal to the cutting direction, respectively.
It is extremely difficult to design a dynamometer in such a way that the two
readings are dependent only on the respective force components. It is the purpose of
this experiment to calibrate a dynamometer and show how corrections can be made
to allow for the so-called cross sensitivity, or interaction, between the two component
readings.

Equipment:
1- A two-component cutting force dynamometer and necessary recording
equipment.
2- A calibration stand with provision for applying the loads in the thrust (horizontal)
and cutting (vertical) directions.

1Page Dr. Ashraf Hassan theory of metal cutting Oct. 2021

 3- A set of 10 weights, each 20 Kg.

Procedure
A diagram of the apparatus assembled for calibration purposes is shown in Fig.11, 1.
A 20-Kg settling weight is first added to each hanger to take up any play in the loading
system, and under this load the recording equipment is balanced and standardized
.Loads in increments of 20 Kg are then added to one component direction, and the
reading on both component indicators noted after each increment. After the maximum
load has been applies, a check for hysteresis is made by repeating the observations
during unloading. This procedure is repeated for the second component, and, finally,
check readings are taken with both components loaded simultaneously with arbitrarily
chosen loads

Analysis of Results
Figure 11.2 shows typical calibration curves obtained for a two-component cutting-
force dynamometer. It can be seen that although the relationships

2Page Dr. Ashraf Hassan theory of metal cutting Oct. 2021

Between the readings obtained and the applied forces are all linear and no hysteresis
is present, each component reading was sensitive to loads applied in the other
component direction. Thus, interaction is present in both components and must be
compensated for by the use of calibration equations.
If the slopes of the lines for the horizontal (Rt) and vertical (Rc) readings are A and C,
respectively, when the dynamometer is loaded in the thrust (Ft) direction and B and D,
respectively, when loaded in the cutting (Fc) direction,
with load components Fc and Ft applied simultaneously the reading for the horizontal
component would be

Rt=AFt+BFc (11.1)

and the reading for the vertical component would be

RC = DFc + CFt (11.2)

3Page Dr. Ashraf Hassan theory of metal cutting Oct. 2021

From (11.1),

Rt  BFc
Ft= (11.3)
A

and from (11.2) ,

Rc  DFc
Ft= (11.4)
C

from (11.3) and (11.4)

Rt  BFc Rc  DFc
 (11.5)
A C

Rearranging Eq, 11.5 gives

ARc  CRt
Fc = (11.6)
AD  BC

And similarly

DRt  BRc
Ft = (11.7)
AD  BC

Equation (11.6) and (Il.7) may be written as

4Page Dr. Ashraf Hassan theory of metal cutting Oct. 2021

 A C
Ft = Rc  Rt
X X
(11.8)
D C
Fc = Rt  Rc
X X

where X = AD - BC.

Equations (11.8) may now be used to calculate Fc, and Ft , from the vertical (Rc) and
horizontal (Rt) component readings obtained during a cutting test.
As a check on the accuracy of the calibration, the readings obtained when
loads are applied simultaneously to both components may be substituted in Eq, (11.8)
and the results compared with the magnitudes of the applied loads.

5Page Dr. Ashraf Hassan theory of metal cutting Oct. 2021