Cutting Force Measurements

S.Dinesh

Purpose of determining cutting forces

Estimation of cutting power consumption Selection of the power source Structural design of the machine Fixture tool system Evaluation of role of the various machining parameters on cutting forces Speed, feed, depth of material, geometry, etc. cut, coolant,

Condition monitoring of the cutting tools and machine tools

Measurement of cutting forces concerns

Magnitude of the cutting forces and their components Directions and locations of action Pattern of the forces : static and / or dynamic

Significance of force components

Resolved into several components
For easiness

Significance of cutting forces

Fz
main or major component It is the largest in magnitude It is also called power component

Fy
May not be that large in magnitude Responsible dimensional inaccuracy and vibration.

Fx least significant
Fig. 1 Cutting force system for single point tool

The two basic methods Analytical methods

Determination of cutting forces

Easy, quick and inexpensive Very approximate and average Effect of several factors not revealed
cutting velocity, cutting fluid action, etc. are not revealed

unable to depict the dynamic characteristics of the forces

Experimental methods
Quite accurate Can reveal effect of variation of any parameter on the forces Both static and dynamic parts of the forces Needs measuring facilities, expertise and hence expensive

General principle of measurement

Fig. 2 General principle of measurement

Principle of cutting force measurement

Measurement of cutting force(s) is based on three basic principles
Measurement of elastic deflection Measurement of elastic deformation Measurement of pressure developed

Measurement of deflection
Fz L

Fig. 3 Cutting tool undergoing deflection, due to cutting force

Measurement of deflection
The deflection() can be measured Mechanically by dial gauge (mechanical transducer) Electrically by using several transducers like
Potentiometer (linear or circular) Capacitive pickup Inductive pickup
LVDT

Mechanical transducer

Force, N

Tan=K

Deflection (), mm
Fig. 4 Calibration of mechanical transducer

Electrical transducers
Fz (a) ri Fz (c) d
Fig. 5 (a) linear pot (b) circular pot (c) capacitive pick up (d) LVDT type

Fz (b)

V Fz (d)

Measurement of elastic deformation

Strain gauges

BM Diagram

Fig. 6 Cutting forces measurement by strain gauges

Working principle of strain gauges

Fig. 7 Force measurement by strain gauge based transducer

Measurement of pressure
emf = tp = voltage sensitivity of the crystal t = thickness of the crystal p = pressure

Fig. 8 Piezoelectric transducer for measuring force

Dynamometer Requirements
For accurate and reliable measurement Sensitivity Rigidity Cross sensitivity Stability against humidity and temperature Quick time response High frequency response Consistency

Types of Dynamometers
Strain gauge type
Inexpensive but less accurate and consistent

Piezoelectric type
Highly accurate, reliable and consistent but very expensive

Turning Dynamometer

Fig. 9 2D Turning Dynamometer

Drilling Dynamometer

Fig. 10 2D Drilling Dynamometer

Milling Dynamometer
Fz Fy Fx Fx

Fz

Fx

Fig. 11 3D Milling Dynamometer

thank you