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    Manufacturing Processes - II: Indian Institute of Technology Delhi

    Uploaded by

    Ethan Hunt
    This document discusses dynamometers for measuring cutting forces in manufacturing processes. It begins by outlining the objectives to explain the general principles of force measurement, types of transducers, and design requirements for dynamometers. It then covers various transduction methods like measuring deflection, strain, or pressure caused by cutting forces. Specific dynamometer designs are presented for turning, drilling, milling, and grinding operations. These include strain gauge and piezoelectric dynamometer types.

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    © All Rights Reserved
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    Manufacturing Processes - II: Indian Institute of Technology Delhi

    Uploaded by

    Ethan Hunt
    7 views21 pages
    This document discusses dynamometers for measuring cutting forces in manufacturing processes. It begins by outlining the objectives to explain the general principles of force measurement, types of transducers, and design requirements for dynamometers. It then covers various transduction methods like measuring deflection, strain, or pressure caused by cutting forces. Specific dynamometer designs are presented for turning, drilling, milling, and grinding operations. These include strain gauge and piezoelectric dynamometer types.

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    L10 MCL136.ppt

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    This document discusses dynamometers for measuring cutting forces in manufacturing processes. It begins by outlining the objectives to explain the general principles of force measurement, types of transducers, and design requirements for dynamometers. It then covers various transduction methods like measuring deflection, strain, or pressure caused by cutting forces. Specific dynamometer designs are presented for turning, drilling, milling, and grinding operations. These include strain gauge and piezoelectric dynamometer types.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    7 views21 pages

    Manufacturing Processes - II: Indian Institute of Technology Delhi

    Uploaded by

    Ethan Hunt
    This document discusses dynamometers for measuring cutting forces in manufacturing processes. It begins by outlining the objectives to explain the general principles of force measurement, types of transducers, and design requirements for dynamometers. It then covers various transduction methods like measuring deflection, strain, or pressure caused by cutting forces. Specific dynamometer designs are presented for turning, drilling, milling, and grinding operations. These include strain gauge and piezoelectric dynamometer types.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 21

    Indian Institute of Technology Delhi

    Manufacturing Processes - II

    Module – 2 : Mechanics of Machining


    (c) Cutting forces and power
    requirement in machining

    Lecture – 10 : Dynamometers for measuring


    cutting forces

    1
    Indian Institute of Technology Delhi

    Specific Instructional objectives :


    To enable the students, at the end of this lecture,
    (i) show the general principle of measurement
    (ii) classify and apply different transducers for
    converting cutting forces into suitable signals
    (iii) State the design requirements for tool - force
    dynamometers
    (iv) develop and use dynamometers for measuring
    cutting forces in
    • Turning
    • Drilling
    • Milling
    • Grinding
    2
    Indian Institute of Technology Delhi
    Physical variable General principle
    (cutting force, temp. etc.) of measurement

    Conversion into another


    suitable variable (deflection, Transducing
    expansion etc) stage (1)
    Signal

    Amplification, filtration and


    stabilization Conditioning
    stage (2)
    Conditioned signal
    Reading or recording Read out
    stage (3)
    3
    Indian Institute of Technology Delhi

    (ii) Various transducers used for measuring


    cutting forces

    The basic principles of measuring cutting forces


    from its effects;
    (a) Monitoring elastic deflection of a body
    caused by the force(s)
    (b) Monitoring elastic deformation, i.e.,
    strain induced by the force(s)
    (c) Monitoring the pressure developed in
    a medium by the force

    4
    Indian Institute of Technology Delhi

    (c) Determination of cutting force(s) by


    measuring deflection(s)
    Basic Principle

     L3  PZ
      PZ  

     3EI  L

    5
    Indian Institute of Technology Delhi

    (a) Methods of measuring deflection caused by


    cutting forces
    • Mechanical device (dial gauge)

     L3 
      PZ  

    PZ
     3EI  L

    6
    Indian Institute of Technology Delhi

    • Measuring deflection by electrical transducers


    PZ
    PZ

    ri
    (a) (b) V
    V
    R PZ
    E

    d
    fixed coil
    (d)
    (c) moving core
    7
    Indian Institute of Technology Delhi

    (b) Determination of cutting forces by measuring


    strain caused by the force(s)
    Large deflection eases monitoring but affects
    machining requirements.
    Principle of measuring force from strain : -
    M = PL PZ
    = M/Z
     = /E L
    R/R   T
    = G Strain
    G = gauge gauges
    C
    factor
    BM diagram 8
    Indian Institute of Technology Delhi

    Determine force by measuring strain,  - contd.

    PZ R3(T)
    R1(T)

    R2(C)
    R4(C)
    GE
    V  1   2   3   4   k1P R1 for balancing
    4
    R2

    R4 R3 SMB

    E
    9
    Indian Institute of Technology Delhi
    (c) Measuring cutting force based on pressure
    created by that force
    • from hydraulic pressure, p
    • from emf generated by the pressure on
    piezoelectric crystal

    Force or pressure

    emf = tp = k2PZ


    Piezoelectric
    t
    crystal Det. K2 by
    emf
    calibration
    10
    Indian Institute of Technology Delhi

    (iii) Design – requirements for Tool - force


    dynamometers

    • sensitivity
    • rigidity
    • cross sensitivity
    • stability against temp. and humidity
    • time response
    • frequency response
    • consistency and durability

    11
    Indian Institute of Technology Delhi

    (iv) Design, construction and use of some


    dynamometers for conventional machining

    Commonly used dynamometers are

    • strain gauge type : simple and low cost but


    less accurate and stable
    • piezoelectric type : more accurate and robust
    but expensive

    12
    Indian Institute of Technology Delhi
    (a) Turning dynamometer
    Strain gauge type and two dimensional

    Aluminium cover

    tool
    shank
    Tool holder

    dynamometer Strain gauges


    13
    Indian Institute of Technology Delhi

    Construction of strain gauge type 2 – D turning


    dynamometer Contd.

    14
    Indian Institute of Technology Delhi

    Piezoelectric type 3 – D turning dynamometer

    15
    Indian Institute of Technology Delhi

    • Drilling dynamometer for torque and thrust


    Strain – gauge type

    Strain gauges
    Strain gauges for torque
    for thrust Job

    gauges
    for thrust

    16
    Indian Institute of Technology Delhi

    Strain gauge type drilling dynamometer

    17
    Indian Institute of Technology Delhi
    Construction and use of a strain gauge type
    3 – D Milling dynamometer

    18
    Indian Institute of Technology Delhi

    • Grinding (surface) dynamometer strain – gauge


    type (with extended O-ring)

    19
    Indian Institute of Technology Delhi

    • Grinding dynamometer – 3 – D piezoelectric type

    end 20
    Indian Institute of Technology Delhi

    THANK YOU

    21

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