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.
REFERENCES (30)
1.
MADHUSUDANA C.K., KUMAR H., NARENDRANATH S., 2016, Condition Monitoring of Face Milling Tool Using K-Star Algorithm and Histogram Features of Vibration Signal, Eng. Sci. Technol. an Int. J., 19, 1543–1551.
2.
LIANG Q., ZHANG D., COPPOLA G., MAO J., SUN W., WANG Y., GE Y., 2016, Design and Analysis of a Sensor System for Cutting Force Measurement in Machining Processes, Sensors, 16/1, 70.
3.
WOJCIECHOWSKI S., MARUDA R.W., BARRANS S., NIESLONY P., KROLCZYK G.M., 2017, Optimisation of Machining Parameters During Ball and Milling of Hardened Steel with Various Surface Inclinations, Measurement, 111, 18–28.
4.
NATH C., BROOKS Z., KURFESS T.R., 2015, Machinability Study and Process Optimization in Face Milling of Some Super Alloys with Indexable Copy Face Mill Inserts, J. Manuf. Process., 20, 88–97.
5.
RIZAL M., GHANI J.A., NUAWI M.Z., HARON C.H.C., 2017, Cutting Tool Wear Classification and Detection Using Multi-Sensor Signals and Mahalanobis-Taguchi System, Wear, 376–377, 1759–1765.
6.
HUANG P.B., MA C., KUO C., 2015, A PNN Self-Learning Tool Breakage Detection System in end Milling Operations, Appl. Soft Comput. J., 37, 114–124.
7.
WANG B., LIU Z., 2016, Cutting Performance of Solid Ceramic end Milling Tools in Machining Hardened AISI H13 Steel, Int. J. Refract. Met. Hard Mater., 55, 24–32.
8.
RIZAL M., GHANI J.A., NUAWI M.Z., HARON C.H.C., 2018, An Embedded Multi-Sensor System on the Rotating Dynamometer for Real-Time Condition Monitoring in Milling, Int. J. Adv. Manuf. Technol., 95, 811–823.
9.
ZHANG S., LI J.F., WANG Y.W., 2012, Tool Life and Cutting Forces in end Milling Inconel 718 Under Dry and Minimum Quantity Cooling Lubrication Cutting Conditions, J. Clean. Prod., 32, 81–87.
10.
AHMADI K., 2017, Analytical Investigation of Machining Chatter by Considering the Nonlinearity of Process Damping, J. Sound Vib., 393, 252–262.
11.
BYRNE G., O’DONNELL G.E., 2007, An Integrated Force Sensor Solution for Process Monitoring of Drilling Operations, CIRP Ann., 56, 89–92.
12.
TOTIS G., WIRTZ G., SORTINO M., VESELOVAC D., KULJANIC E., KLOCKE F., 2014, Development of a Dynamometer for Measuring Individual Cutting Edge Forces in Face Milling, Mech. Syst. Signal Process., 24, 1844–1857.
13.
QIN Y., ZHAO Y., LI, Y., ZHAO Y., WANG P., 2017, A Novel Dynamometer for Monitoring Milling Process, Int. J. Adv. Manuf. Technol. 92, 2535–2543.
14.
XIE Z., LU Y., LI J., 2017, Development and Testing of an Integrated Smart Tool Holder for Four-Component Cutting Force Measurement, Mech. Syst. Signal Process., 93, 225–240.
15.
LIU M., BING J., XIAO L., YUN K., WAN L., 2018, Development and Testing of an Integrated Rotating Dynamometer Based on Fibber Bragg Grating for Four-Component Cutting Force Measurement, Sensors, 18, 1254.
16.
LUO M., LUO H., AXINTE D., LIU D., MEI J., LIAO Z., 2018, A Wireless Instrumented Milling Cutter System with Embedded PVDF Sensors, Mech. Syst. Signal Process., 110, 556–568.
17.
DINI G., TOGNAZZI F., 2007, Tool Condition Monitoring in end Milling Using a Torque-Based Sensorized Toolholder, Proc. Inst. Mech. Eng., Part B, J. Eng. Manuf., 221, 11–23.
18.
RIZAL M., GHANI J.A., NUAWI M.Z., HARON C.H.C., 2015, Development and Testing of an Integrated Rotating Dynamometer on Tool Holder for Milling Process, Mech. Syst. Signal Process., 52–53, 559–576.
19.
QIN Y., WANG D., YANG Y., 2020, Integrated Cutting Force Measurement System Based on MEMS Sensor for Monitoring Milling Process, Microsyst. Technol., 26, 2095–2104.
20.
TOTIS G., ADAMS O., SORTINO M., VESELOVAC D., KLOCKE F., 2014, Development of an Innovative Plate Dynamometer for Advanced Milling and Drilling Applications, Measurement, 49, 164–181.
21.
SUBASI O., YAZGI S.G., LAZOGLU I., 2018, A Novel Triaxial Optoelectronic Based Dynamometer for Machining Processes, Sensors Actuators, A Phys., 279, 168–177.
22.
GOMEZ M., SCHMITZ T., 2020, Low-Cost, Constrained-Motion Dynamometer for Milling Force Measurement, Manuf. Lett., 25, 34–39.
23.
SANDWELL A., LEE J., PARK C., PARK S.S., 2020, Novel Multi-Degrees of Freedom Optical Table Dynamometer for Force Measurements, Sensors Actuators A. Phys., 303, 111688.
24.
LI Y., ZHAO Y., FEI J., QIN Y., ZHAO Y., CAI A., GAO S., 2017, Design and Development of a Three-Component Force Sensor for Milling Process Monitoring, Sensors, 17, 1–18.
25.
YALDIZ S., UNSAÇAR F., SAGLAM H., ISIK H., 2007, Design, Development and Testing of a Four-Component Milling Dynamometer for the Measurement of Cutting Force and Torque, Mech. Syst. Signal Process., 21, 1499–1511.
26.
MOHANRAJ T., SHANKAR S., RAJASEKAR R., UDDIN M.S., 2020, Design, Development, Calibration, and Testing of Indigenously Developed Strain Gauge Based Dynamometer for Cutting Force Measurement in the Milling Process, J. Mech. Eng. Sci., 14, 6594–6609.
27.
ALIPANAHI A., MAHBOUBKHAH M., BARARI A., 2022, Cross-Sensitivity Control in a Novel Four-Component Milling Dynamometer for Simultaneous Measurement of Tri-Axial Forces and Torque, Measurement, 191, 110788.
28.
FIORILLO A.S., CRITELLO C.D., PULLANO S.A., 2018, Theory, Technology and Applications of Piezoresistive Sensors: A review, Sensors Actuators A. Phys., 281, 156–175.
29.
LI X., HE H., MA H., 2019, Structure Design of Six-Component Strain-Gauge-Based Transducer for Minimum Cross-Interference via Hybrid Optimization Methods, Struct. Multidiscip. Optim., 60, 301–314.
30.
LYU Y., JAMIL M., HE N., GUPTA M.K., 2021, Development and Testing of a High-Frequency Dynamometer for High-Speed Milling Process, Machines, 9, 11.
CITATIONS (1):
1.
Coupling characteristic of column-type six-component force/moment transducers
Wei Liang, Zhenting Xu, Zhijie Xie, Xiaodong Hong, Jianfeng Zhong, Shuncong Zhong, Shuo Lin
Measurement
Wei Liang, Zhenting Xu, Zhijie Xie, Xiaodong Hong, Jianfeng Zhong, Shuncong Zhong, Shuo Lin
Measurement
| eISSN: | 2391-8071 |
| ISSN: | 1895-7595 |
We process personal data collected when visiting the website. The function of obtaining information about users and their behavior is carried out by voluntarily entered information in forms and saving cookies in end devices. Data, including cookies, are used to provide services, improve the user experience and to analyze the traffic in accordance with the Privacy policy. Data are also collected and processed by Google Analytics tool (more).
You can change cookies settings in your browser. Restricted use of cookies in the browser configuration may affect some functionalities of the website.
You can change cookies settings in your browser. Restricted use of cookies in the browser configuration may affect some functionalities of the website.
