• Cutting forces are strongly related for understanding the

principles of MACHINING.
• Dynamometer is designed for integrating it with cutting
tool and examining the forces acting on tool or cutting force

• Mainly consists of cutting insert, tool holder, dynamometer

plate and SENSOR

CUTTING INSERT FOR STEEL

TURNING INSERT
 SENSOR

• Sensor for integrating the dynamometer with the

cutting tool is designed after performing several
experiments with different configurations.
• The experiments resulted in various information
regarding bandwidth of freq. , max and min force…

 The following criteria were considered during the design and

optimization phase:

 Static receptances measured at cutting insert tip along the three

Reference commercial
dynamometer adapted for
the application on the tool
head of a multi-function
CN lathe
main directions X, Y and Z should be minimized, in order to limit
undesired tool deflections during machining.
 The levers along X, Y and Z directions between insert tip and
sensor centre should be minimized, in order to limit bending and
torsion moments acting on the sensor, which may cause undesired
sensor rotations or crosstalk effects.
 Natural frequencies of the whole system including the tool-holder
should be maximized and masses in front of the sensor should be
minimized in order to improve sensor dynamics.
 Maximum Maximum bandwidth in
Sensor structure Type
force(N) operating conditions(kHz)
Strain gauges stacked on a special tool holder
close to circular holes enhancing local Tri - axial 100 Not specified
deformation
Strain gauges sticked on parallel beam type
toolholder, obtained with new circular holes Tri - axial 4000 1.6(Fx), 0.8(Fy), 3(Fz)
design
Strain gauges attached on toolholder endowed
Mono - axial 1000 Not specified
with infra-red data transmission device

Combined-type tool dynamometer based on strain

Tri – axial 15 2.35
gauges and piezo film-type accelerometer
Strain gauges mounted on the tool holder (boring
Tri – axial 1000 3
bar)
Strain gauges attached on flexible octagonal rings
Tri – axial 3500 0.16
embedded into tool holder
Optical fibre detecting the vibration of the rear
Mono – axial 1000 0.95
part of the tool shank
Piezoelectric plate dynamometer Kistler 9121 to 3000(Fx,y),
Tri – axial fn < 1
be installed on lathe turret 6000 (Fz)
Piezoelectric plate dynamometer Kistler 9257B Tri – axial 5000 fn <1
Piezoelectric plate dynamometer Kistler Compact 500 ( fx , fy )
Tri - axial Not specified
Dyn 9254 1000 (fz)
Slim line KISTLER 9132B placed under the cutting
Mono axial 7000 Not specified
insert
 In the light of the limitations affecting the reference configuration,
new sensor specifications were expressed as follows:
 Tri – axial force measurement during standard turning operations
(10N < Fc < 5 kN).
 Good static characteristics (relative static error < 5%, crosstalk
disturbance < 3%, low tool tip receptance ~ 0.1 m/N along all
directions).
 Good dynamic behavior (frequency bandwidth Z1 kHz along all
directions).
 Compatibility with different cutting insert geometries (both
positive and negative, 551 and 801 rhombic inserts).
 Compatibility with the tool – head of an OKUMA MULTUS B300
multi-function machine tool.
 Lubricant resistant.
Comparison between: state of the art and new sensor configuration
DESCRIPTION SYMBOL PLATE DYN. NEW SENSOR
KISTLER 9129AA SYSTEM
Total mass including adapter M (g) 10269 3642
Mass in front of the sensor m (g) 1068 120
Tool tip static compliance along X hxx (mm/N) 0.047 0.093
Tool tip static compliance along Z hzz (mm/N) 0.052 0.070
First natural frequency along X fnat,x (Hz) 571 1014
First natural frequency along Z fnat,z (Hz) 558 1177

Exploded view of the new sensor FINAL PROTOTYPE MOUNTED ON THE

configuration CNC MACHINE TOOL
 Correlation between measured and predicted cutting forces

CONCLUSIONS
 Difficulties in estimating cutting forces can be eliminated through various
problem solving techniques
 Predicting the cutting force in machining processes can be
instantaneously derived
 Precautions and methodologies to maintain tools and machines can be
found.