Design and Optimization of a Cross-Beam Force Transducer for a Stationary Dynamometer for Measuring Milling Cutting Force
1
Department of Mechanical Engineering, Faculty of Engineering, Syiah Kuala University (USK), Darussalam, Banda Aceh 23111, Indonesia, Syiah Kuala University, Indonesia
2
Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, UKM, Bangi 43600, Malaysia, Universiti Kebangsaan Malaysia, Malaysia
Submission date: 2023-02-12
Final revision date: 2023-03-21
Acceptance date: 2023-03-22
Online publication date: 2023-03-24
Publication date: 2023-06-12
Corresponding author
Muhammad Rizal
Department of Mechanical Engineering, Faculty of Engineering, Syiah Kuala University (USK), Darussalam, Banda Aceh 23111, Indonesia, Syiah Kuala University, Indonesia
Department of Mechanical Engineering, Faculty of Engineering, Syiah Kuala University (USK), Darussalam, Banda Aceh 23111, Indonesia, Syiah Kuala University, Indonesia
Journal of Machine Engineering 2023;23(2):41–65
KEYWORDS
TOPICS
ABSTRACT
This paper’s objective is to design and optimize a force transducer to build a stationary dynamometer that can measure three axes of milling cutting force. To reduce interference error and increase sensitivity, the force transducer's Maltese cross-beam design was optimized. The force transducer's performance depends on three design parameters: the cross-rectangular beam's through-hole length and width, the compliant plate thickness, and the strain, stress, and stiffness of force transducer constructions calculated by ANSYS. The response surface method (RSM) estimates a desired second-order polynomial function for three geometric parameters based on sensitivity, interference error, safety factor, and stiffness. A stationary dynamometer prototype was made with four optimized force transducers and several piezoresistive strain sensors. The developed dynamometer has good linearity, repeatability, and hysteresis, as well as high sensitivities and low cross-sensitivity errors. The reference dynamometer's cutting force measurements were very close to those of the designed dynamometer in the validation test.
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