Chapter 5: Tool Dynamometers

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1 Chapter 5: Tool Dynamometers LEARNING OBJECTIVES Different types of transducers used in Dynamometers Design Requirements Types of Dynamometers Introduction: Dynamometers are devices used to measure cutting forces in machining operation. The cutting force cannot be detected or quantified directly but their effect can be sensed using Transducer. For example, a force which can neither be seen nor be gripped but can be detected and also quantified respectively by its effect and the amount of those effects (on some material) like elastic deflection, deformation, pressure, strain etc. These effects, called signals, often need proper conditioning for easy, accurate and reliable detection and measurement. In other words, Measurement involves three stages Conversion into another suitable variable (deflection, expansion etc) Amplification, filtration and stabilization Reading or recording Measurement of cutting force(s) is based on three basic principles: measurement of elastic deflection of a body subjected to the cutting force measurement of elastic deformation, i.e. strain induced by the force measurement of pressure developed in a medium by the force. Measuring deflection caused by the cutting force(s) Under the action of the cutting force, say F C in turning, the tool or tool holder elastically deflects as indicated in Fig.1 Such tool deflection, δ is proportional to the magnitude of the cutting force, F C, simply as, Treating the tool as a cantilever beam, we can write the deflection of the tool as Since for a given cutting tool and its holder, E and I are fixed, we can write, δ F C Compiled by: Jagadeesha T, Assistant Professor, MED, National Institute of Technology, Calicut 1

2 Fig.1: Deflection of the cutting tool. The deflection, δ, can be measured mechanically by dial gauge (mechanical transducer) electrically by using several transducers like; potentiometer; linear or circular capacitive pickup inductive pickup LVDT ( Linear Variable Differential Tranformer) Figure 2: Electrical transducers working based on deflection measurement (a) linear pot (b) circular pot (c) capacitive pick up (d) LVDT type Compiled by: Jagadeesha T, Assistant Professor, MED, National Institute of Technology, Calicut 2

3 Under the action of the cutting force, say F C in turning, the tool or tool holder elastically deflects as indicated Figure 3 deflections versus load In case of mechanical measurement of the tool deflection by dial gauge, calibration is done by employing known loads, W and the corresponding tool deflections, δ are noted and then plotted as shown in Fig. 3. Here the slope of the curve represents the constant, k of the equation δ = k (constant) F C The capacitative pick up consists of two plates with an intervening air gap. The mechanical deformation causes a change in air gap, thus changing the capacitative effect. Fig. 4 Capacitative pick up dynamometer Measuring cutting force by monitoring elastic strain caused by the force. Increasing deflection, δ enhances sensitivity of the dynamometer but may affect machining accuracy where large value of δ is restricted, the cutting forces are suitably measured by using the change in strain caused by the force. Fig. 4 shows the principle of force measurement by measuring strain, ε, which would be proportional with the magnitude of the force, F (say F c ) as, Compiled by: Jagadeesha T, Assistant Professor, MED, National Institute of Technology, Calicut 3

4 Figure 4: Measurement of cutting force by strain gauges M = Bending moment Z = Sectional modulus of the tool section I = plane moment of inertia of the plane section y= distance of straining surface from the neutral plane of the beam The strain, ε induced by the force changes the electrical resistance, R, of the strain gauges which are firmly fixed/pasted on the surface of the tool-holding beam as 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 Figure 5. Figure 5: Force measurement by strain gauge based transducer. Out of the four gauges, R 1, R 2, R 3 and R 4, two are put in tension and two in compression as shown in Fig. 4. The output voltage, V, depends upon the constant, G and the summation of strains as, Compiled by: Jagadeesha T, Assistant Professor, MED, National Institute of Technology, Calicut 4

5 Measuring cutting forces by pressure caused by the force This type of transducer functions in two ways : the force creates hydraulic or pneumatic pressure (through a diaphragm or piston) which is monitored directly by pressure gauge as indicated in Figure 6. the force causes pressure on a piezoelectric crystal and produces an emf proportional to the force or pressure as indicated in Figure 7. emf = λtp where λ = voltage sensitivity of the crystal t = thickness of the crystal p = pressure Figure 6: Force measurement by strain gauge based transducer Figure 7 : Force measurement by strain gauge based transducer Compiled by: Jagadeesha T, Assistant Professor, MED, National Institute of Technology, Calicut 5

6 Requirement of a cutting force dynamometer The dynamometer should have sufficient mechanical rigidity to avoid excessive deformation of the cutting edge under the action of cutting forces It should have sufficient sensitivity to enable measurement of cutting forces with sufficient accuracy It should have high stiffness and low mass, ensuring 100 percent transmissibility of force by its very high natural frequency. This feature will also enable the recorded force to be unaffected by the exciting vibration due to machining process itself. Example : milling, grinding and shaping It should be capable of indicating individual force components without any cross effect, while measuring such forces simultaneously The measuring system should be stable with reference to time, temperature and humidity, requiring only occasional checking after calibration. Compiled by: Jagadeesha T, Assistant Professor, MED, National Institute of Technology, Calicut 6

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