Design and analysis of a strain gauge based eight-shaped elliptical ring dynamometer for milling force measurement

Abstract

This study describes the design, analysis, and development of a strain gauge-based dynamometer for measuring the cutting force during the milling process. The objective is to increase the deformation of the ring with an applied load so that it can be measured more easily. Based on the analysis and test results, the eight-shaped (ES) rings with an elliptical hole were finalized. It was shown that the ring has a higher deformation of 0.02822 mm for a normal load and 0.2136 mm for a tangential load. Also, the induced von Mises stress is 39.63 MPa for axial and 194.8 MPa for tangential load, each of which is less than half of the yield strength. Hence, for the finalized design the metallic ring was fabricated, and sensors were bonded. Then, the calibration and metrological characterization was performed. Overall, the designed dynamometer is found as suitable for measuring the cutting force in the milling process.

Review on sensor design for cutting force measurement

“…This can be obtained by increasing the thickness of the material at the shear zone by modifying the circular ring into an elliptical ring element, as shown in Figure 5. 46…”

“…This can be obtained by increasing the thickness of the material at the shear zone by modifying the circular ring into an elliptical ring element, as shown in Figure 5. 46 During the fabrication of the ring element, the dimensional accuracy has to be appropriately maintained to enhance the performance. The essential characteristics are sensitivity, cross-sensitivity, accuracy, and linearity.…”

“…20 Recently, piezoceramic thick film sensor was used to measure the milling force. 27 The numerous ring elements like circular ring, 28,29 diaphragm type, 30 elastic body, 31 bending beam, 32,33 hexagonal ring, 34 square ring, 29 modified square ring, 35 octagonal ring, 25,[36][37][38][39][40][41][42][43] two extended octagonal rings, 44 octagonal-elliptical ring, 45 eight-shaped elliptical ring, 46 and G & S-shaped ring 47 were used as a sensing element for force transducers. The review on cutting force measurement using different dynamometers is not published to the author's knowledge.…”

Prediction of Flank Wear during Turning of EN8 Steel with Cutting Force Signals Using a Deep Learning Approach

“…Tool condition has been monitored by measuring the various sensor signals like cutting force, vibration [4], and sound signals [5]. Cutting force (CF) can be measured with piezoelectric or strain gauge-based sensors [6,7]. Te I-Kaz method analyzed a low-cost strain gauge sensor that measured the CF signals.…”

Development of a novel strategy based on in-process compensation of charge leakage for static force measurement by piezoelectric force sensors

“…In practical applications of ultra-precision machining, semiconductor industry and biomechanics field, there are many cases where it is necessary to measure static or quasistatic micro forces by force sensors, such as constant cutting force machining and measuring machining forces in real time for monitoring the machining status [14,15], micro constant force servo for surface measurement [5], sensing and positioning based on force signal [7,9], etc. The force gauge based on the principle of strain gauge can measure static force [16], but its sensitivity and stiffness are much lower than the piezoelectric sensor so that the application of the piezoelectric sensor could not be replaced by the commercial force gauge. Therefore, it is necessary to develop the static and quasi-static force measuring capability of the piezoelectric force sensors.…”