Design and Fabrication of a Strain Gauge Type 3-axis Milling Tool Dynamometer: Fabrication and Testing

Design and Fabrication of a Strain Gauge Type 3-axis Milling Tool Dynamometer: Fabrication and Testing

Bhargav Prajwal Pathri (Malaviaya National Institute of Technology, Jaipur, India), Arpit Kumar Garg (National Institute of Technical Teacher's Training and Research, Chandigarh, India), Deepak Rajendra Unune (Malaviya National Institute of Technology, Jaipur, India), Harlal Singh Mali (Malaviya National Institute of Technology Jaipur, India), Sukhdeep S. Dhami (National Institute of Technical Teacher's Training and Research, Chandigarh, India) and Ravindra Nagar (Malaviya National Institute of Technology Jaipur, India)
DOI: 10.4018/IJMFMP.2016070101
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Abstract

This paper presents the design and development of low cost strain gauge type milling tool dynamometer, which is suitable for measuring milling forces. The designed dynamometer contains four octagonal ring members on which strain gauges were bonded. The strain induced on the strain gauges due to milling forces during cutting was measured in terms of voltages using a Wheatstone bridge. A data acquisition system was connected to the dynamometer to acquire the data. The end milling operation was carried out on AISI 1020 steel work pieces of 60 mm x 30mm x 20 mm size using different combination of cutting parameters designed by design of experiments Taguchi approach on CNC milling machine. Machining tests were performed at different cutting parameters and measured cutting forces were compared with those measures by Kistler Dynamometer. The results showed that the dynamometer could be used reliably.
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2. Materials And Method

A three-force component milling tool dynamometer capable of measuring, cutting forces during metal cutting was designed and constructed. A computer connection for data acquisition was also made and this setup was calibrated with the help of a universal testing machine. Figure 1 shows the schematic representation of the cutting force measurement system.

Figure 1.

Schematic representation of cutting force measurement system

2.1. Dynamometer

The designed and constructed dynamometer is capable of measuring the primary cutting force (Fc), feed force (Ff) and radial force (Fr). This dynamometer consists of four elastic octagonal rings on which strain gauges were mounted, and necessary connections were made to form Wheatstone bridges, as shown in Figure 2. These rings are fixed and held between two metal plates. Figure 3 gives the Wheatstone bridge connections for Fc, Ff, and Fr forces.

Figure 2.

Schematic diagram showing location of strain gauges and the orientation of octagonal rings

Figure 3.

Circuit diagram for Fr, Ff and Fc forces

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