Design and Development of a Tri-Axial Turning Dynamometer Utilizing Cross-Beam Type Force Transducer for Fine-Turning...

Area of Science:

• Mechanical Engineering
• Manufacturing Technology
• Instrumentation

Background:

• Accurate measurement of cutting forces is crucial in machining operations.
• Existing dynamometers may suffer from cross-talk and limited sensitivity.
• Tri-axial force measurement is essential for comprehensive analysis of turning operations.

Purpose of the Study:

• To design and develop a novel cross-beam force transducer for a tri-axial dynamometer.
• To improve sensitivity and reduce interference error compared to traditional Maltese cross-beam designs.
• To create a reliable system for simultaneous measurement of cutting forces along three axes during turning.

Main Methods:

• Finite element analysis (FEA) was used to investigate strain distribution and optimize sensor placement.
• Piezoresistive strain gauges were integrated into the transducer prototype.
• Calibration tests were conducted in three perpendicular directions to assess performance metrics.
• Modal analysis and experimental turning tests were performed to evaluate dynamic capabilities.

Main Results:

• The modified Maltese cross-beam design demonstrated higher sensitivity and reduced cross-talk error.
• FEA provided insights into optimal strain gauge locations.
• Calibration tests confirmed linearity, hysteresis, and repeatability.
• Experimental tests validated the dynamometer's suitability for real-world turning applications.

Conclusions:

• The developed tri-axial dynamometer offers a reliable and accurate solution for measuring cutting forces in machining.
• The improved force transducer design overcomes limitations of previous approaches.
• This technology enables precise monitoring and control of turning processes.