To Design, Develop and Test Strain Gauge Based Dynamometer for Measuring Cutting Forces in Turning

Abstract

A great amount of engineering world uses processes like casting, molding and forming for manufacturing of products of distinct shapes and sizes to satisfy customer’s needs. But to attain final and fine shape of the product offers several metal cutting processes before it is ready to use. In material cutting processes to obtain products with maximized quality and reduced cost demands some much needed factors like appropriate selection of tool material, parameters affecting cutting condition, tool structural features etc. Attempts made to achieve this goal got attention for research on computation and estimation of machining forces generated during any metal cutting process. Experimental and real-time acquiring of the cutting forces data has been indispensable because theoretically calculated results of cutting forces vary to a large extent when geometry of the tool is intricate, cutting conditions are fluctuating regularly and some uncounted factors or stresses are induced. For this purpose, development of dynamometers is very essential. Through this project an attempt is being made to design, develop, calibrate and experimentally test a dynamometer, with strain gauges as sensors mounted, for measuring cutting forces generated during turning of metallic parts. The constructed device is experimentally tested against experimental results acquired via highly reliable commercial dynamometer by comparing forces results for cutting of Aluminum 6061-T6. Obtained results proved the excellent characteristics of the designed device and its effectiveness for investigating advanced machining applications.