Measurement 39 (2006) 80–89

www.elsevier.com/locate/measurement

A dynamometer design for measurement the cutting

forces on turning
Süleyman Yaldız *, Faruk Ünsaçar
Mechanical Department, Technical Education Faculty, Selçuk University, 42031 Konya, Turkey

Received 30 July 2004; received in revised form 12 July 2005; accepted 21 July 2005
Available online 30 September 2005

Abstract

The cutting forces generated in metal cutting have a direct influence on generation heat, tool wear or failure, quality
of machined surface and accuracy of the work piece. In this study, a turning dynamometer that can measure static and
dynamic cutting forces by using strain gauge and piezo-electric accelerometer respectively has been designed and con-
structed. The orientation of octagonal rings and strain gauge locations has been determined to maximize sensitivity and
to minimize cross-sensitivity. The force signals were captured and processed using proper data acquisition system. The
dynamometer has been subjected to a series of tests to determine its static and dynamic characteristics. The results
obtained showed that the dynamometer could be used reliably to measure static and dynamic cutting forces.

2005 Elsevier Ltd. All rights reserved.

Keywords: Dynamometer; Strain gauge; Data acquisition; Turning

1. Introduction work piece, the process of chip formation, chatter

Force measurement in metal cutting is essential
requirement as it is related to machine part design,
tool design, power consumptions, vibrations, part
accuracy, etc. It is the purpose of the measurement
of cutting force to be able to understand the cut-
ting mechanism such as the effects of cutting vari-
ables on the cutting force, the machinability of the
*
Corresponding author. Tel.: +90 332 223 2347; fax: +90 332
2410185.
E-mail address: syaldiz@selcuk.edu.tr (S. Yaldız).
and tool wear [1]. It has been observed that the
force values obtained by engineering calculations
contain some errors when compared with experi-
mental measurements. The cutting force even in
steady state conditions is affected by many param-
eters and the variation of cutting force with time
has a peculiar characteristic [2]. The need for mea-
surement of all cutting force component arises
from many factors, but probably the most impor-
tant is the need for correlation with the progress of
tool wear [3]. If this can be obtained, it will be pos-
sible to achieve tool wear monitoring in turning

0263-2241/$ - see front matter
2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.measurement.2005.07.008
 S. Yaldız, F. Ünsaçar / Measurement 39 (2006) 80–89
based on force variation. The reason for the cut-
ting force measurement is that it is a good indica-
tor in detecting tool wear. It is well known that
during the cutting process, the cutting parameters
such as cutting speed, feed rate and depth of cut
often present a deviation from the calculated val-
ues. For this purpose, many dynamometers have
been developed [4]. In these dynamometers, cut-
ting force measurement is mainly based on elastic
deformation of the materials.
Various studies concerning dynamometer
design and construction can be found in the pub-
lished Ref. [5,6]. Force components in turning
are often measured using either an octagonal-ring
dynamometer type or a tool shank type. The tool-
shank type is always characterized by its inaccu-
racy and insensitivity in measuring either one or
two components [7].
The strain gauge produces a clear relation be-
tween the measured quantity and the strain on a
suitable spot on the spring element [8]. In most
cases, the static force is obtained by a strain gauge
type sensor which produces an output voltage pro-
portional to elastic deformation.
The cutting force dynamometers must be man-
ufactured at sufficient accuracy and high rigidity,
and particularly suitable for dynamic loads [9].
Ito et al. [10] designed some strain gauge based
Fig. 1. Schematic representation of experimental set-up.
81
dynamometers that can be adapted to some
machine tools and defined the criterions of their
rigidity and sensitivity. In designing dynamometer,
some principles such as parallel beam type [1,11],
circular hole [7,6], piezo-electric [12,13], etc., have
been used widely.
This study outlines a strain gauge based octag-
onal-ring type analogue dynamometer design and
prototyping. This dynamometer is capable of mea-
suring three-force components. As the reading of
analogue values manually is a difficult and tedious
job, a computer connection for data acquisition
has been realized.
2. Experimental set-up
2.1. Dynamometer
A three-force component analogue dynamom-
eter capable of measuring cutting forces during
turning was designed, developed and tested. A
computer connection for data acquisition was also
made and calibrated. The analogue data can be
evaluated numerically on a computer and when re-
quired can be converted back to analogue. The
schematic representation of the cutting force mea-
surement system is capable of measuring feed force
82 S. Yaldız, F. Ünsaçar / Measurement 39 (2006) 80–89

Table 1
Experimental equipments and their technical properties
Machine tool Harrison Universal Lathe Model M300
Dynamometer Strain gauge based three component cutting force dynamometer
Strain gauge HBM: LY11 6/120; effective gauge length 6 mm; gauge factor 2.03 ± 1%; gauge resistance
350 ± 0.35%X; transverse sensitivity of
0.2%
Strain ring Octagonal in shape; made of AISI 4140 steel; b = 20 mm; r = 16 mm; t = 4 mm
Strain amplifier Advantech: ADAM 3016
Data acquisition card Advantech: A/D converter; PCI 1712, 16 single channel (8 differential), 1–10 MHz
Data recording software Written in C; capable of recording, simulating and data processing
Piezo-electric accelerometer Kistler: 8632C50; sensitivity 100 mV/g; output voltage ±5 V; current 2 mA;
transverse sensitivity 1%max; power supply 10–30 VDC
Coupler/power supply Kistler: 5118B2; bandwidth 0.03, 0.006 Hz; gain 1·, 10·, 100·; output voltage ±10 V;
operated by internal battery (4 · 1.5 V) or external voltage 6–28 VDC
Universal testing machine LLOYD Instrument T = 50 K

(Ff), thrust force (Ft) and main cutting force (Fc)
which occurs during turning operations as seen
in Fig. 1. This dynamometer consists of four elas-
tic octagonal rings on which strain gauges were
mounted and necessary connections were made
to form measuring the Wheatstone bridges.
2.2. Data acquisition
On-line and real-time information of the cutting
force data are automatically read and stored by a
system during metal cutting. Since the output from
Wheatstone bridge circuits is very low due to the
high stiffness requirement of the dynamometer,
the analogue signals coming from dynamometer
amplified by strain gauge input modules (Advan-
tech ADAM 3016) are then converted to digital
signals and captured by PCI-1712 data acquisition
card installed in MS-Windows based PC. The
stored data can be retrieved and used for analysis
when required. The data acquisition software is
capable of averaging and graphical simulation of
force signals in process. The lists of the experimen-
tal equipments used are shown in Table 1.
3. Design and construction of a dynamometer for
turning
3.1. The criterions for dynamometer design
The rigidity and sensitivity are two opposing
but basic requirements in dynamometer design.
In addition, the structure of the dynamometer
has to meet more strict requirements concerning
the natural frequency and wide frequency response
and small cross-sensitivity. The ring elements must
be machined identical and symmetrical to prevent
cross-sensitivity and they should have certain sur-
face quality and high measurement tolerance. The
mechanical properties of strain rings must be
determined experimentally.
A dynamometer essentially consists of an
important ring element. The rigidity, high natural
frequency, corrosion resistance and high heat con-
ductivity factors were taken into consideration
while selecting the ring materials. Also, deforma-
tion under the load should conform to that of
strain gauges [14].
In this study, AISI 4140 steel, which meets
above requirements, was selected as the ring
material.
3.2. Determination of dimensions of the
octagonal rings
The thickness t, radius r, and width of the circu-
lar strain ring b are the three basic controllable
parameters that affect the rigidity and sensitivity.
Since there is no effect of ring width b and modulus
of elasticity (E) on the strain per unit deflection, bmin
can be taken as 20 mm to setup the rings securely [9].
The deformation of circular ring under the ef-
fect of thrust force Ft and main cutting force Fc
separately is shown in Fig. 2b and c respectively.
As long as strain on A and B where the strain
 S. Yaldız, F. Ünsaçar / Measurement 39 (2006) 80–89
Fig. 2. The deformation of circular strain ring under: (a) combined, (b) thrust Ft and (c) main cutting Fc forces.
gauges are going to be fixed (Fig. 2a) are within the
elastic limits of the ring material, the strain and
deflection due to the main cutting force should
be considered for the purpose of the ring design
for maximization of sensitivity (ec/Fc) and stiffness
(Fc/dc).
The strain gauges should be placed where the
stress concentration has maximum value. The
experiments have shown that good results are ob-
tained for octagonal rings when the inclined
gauges are at points 45 from the vertical instead
of 39.6 required by the circular ring theory. The
strain per unit deflection can be expressed as [9]
et 1:09t t Ebt2
¼ ffi 0:61
dt =r 1:8r r 2:18F c r
where dt is the deflection in a radial direction and et
is the strain due to thrust force Ft. It is clear that
for maximum sensitivity and rigidity et/dt should
be as large as possible. This requires that r should
be as small as possible and t as large as possible.
But small r brings some difficulties in mounting
the internal strain gauges accurately. Therefore,
for a given size of r and b, t should be large enough
to be consistent with the desired sensitivity. Ito
et al. [10] performed a finite element analysis for
the elastic behaviour of octagonal rings. They ex-
pressed that the octagonal ring is substantially stif-
fer than the circular ring when t/r equals 0.05 or
less, the difference in displacement of circular ring
and octagonal ring is less than 10% if t/r equals
0.25 or greater. In order to be consistent with this
expression, the ring thickness and ring radius were
taken as 4 and 16 mm respectively. Thus, the rate
of t/r (4/16 = 0.25) provides corresponding sensi-
tivity to stiffness ratio e/(d/r) for octagonal ring.
83
3.3. Verifying the dimensions of octagonal rings
The maximum expected force, which the rings
may face in each direction, is assumed as 3500 N.
If the cross-sectional dimensions of a curved bar
is smaller than the radius of the centre line, it is
considered to be thin ring [15]. Taking into ac-
count dimensions as; width (b) = 20 mm; radius
(r) = 16 mm; thickness (t) = 4 mm, elastic strains
et and ec due to forces Ft and Fc are calculated
according to ring theory by using the following
equations [7,9]:
1:09F t r
et ¼  ¼ 9:1  10
4 ð2Þ
ð1Þ
ec ¼  ¼ 1:82  10
3 ð3Þ
Ebt2
The stress occurring on rings caused by thrust and
main cutting forces can be calculated by placing
elastic strain ratio values in Eq. (4) and (5) as
follows:
rt ¼ Eet ¼ 190:8 N=mm2 ð4Þ
rc ¼ Eec ¼ 381:5 N=mm 2
ð5Þ
As the yield strength of AISI 4140 steel is 550–
900 N/mm2, the calculated stress values (rt and
rc) occurring on the rings are within safety limits
for this material.
3.4. Dynamic properties of dynamometer
Vibration frequency of the machine tool, to
which the dynamometer is mounted for cutting
force measurement, should conform to the natural
frequency of the dynamometer. A dynamometerÕs
natural frequency should be as high as possible.
84 S. Yaldız, F. Ünsaçar / Measurement 39 (2006) 80–89

As placing the related values in Eq. (6), the ring

Fig. 3. Free-body diagram of the developed dynamometer.
Vibration frequency of the machine tool is related
to the spindle speed of the machine tool. The dyna-
mometer should have natural frequency of at least
four times the vibration frequency of the machine
tool [9]. The dynamometer is considered to be a
small mass supported by ring elements for analyt-
ical purpose as shown in Fig. 3.
In order to determine the natural frequency of
the dynamometer, the ring constant of dynamom-
eter should be determined first. The stiffness value
for a thin circular ring is given as in the following
equation [9]:
Ft Ebt3
Kt ¼ ¼ ð6Þ
dt 1:8r3
constant of the dynamometer is computed as;
Kt = 36,458 N/mm.
The natural frequency of dynamometer, which
is assumed to be a small mass supported by ring
elements, can be obtained from the following rela-
tion [9]:
1 pffiffiffiffiffiffiffiffiffiffi
fd ¼ K=m ð7Þ
2p
where; K dynamometer ring constant (N/mm), m
dynamometer mass (kg), fd dynamometer natural
frequency (rev/s).
The ring mass is 36.43 kg. As placing the related
values in Eq. (7), the natural frequency of dyna-
mometer is computed as fd = 159.2 rev/s. To fulfil
the requirement as stated above fd > 4fm, the max-
imum spindle speed of the lathe should be 200
rev/s or 12,000 rpm.
3.5. The orientation of the strain gauges and the
rings on the dynamometer
The proper selection of the points where the
strain gauges are mounted is essential for achiev-
ing high accuracy in the Wheatstone bridge cir-
cuits. The orientation of the strain gauges on the

Ft Section L- L Section W-W

1 2 5 6 9 10 13 14
3 4 8 7 11 12
A C B D16 15

W Strain guages

C
B Y

Ff
L
X
A Fc D

L
W

Fig. 4. The strain gauges and ring orientation on the dynamometer.

 S. Yaldız, F. Ünsaçar / Measurement 39 (2006) 80–89
rings and the position of the rings on the dyna-
mometer are given in Fig. 4.
The thrust force Ft are supported by A, B, C
and D rings of the dynamometer as shown in
Fig. 4. The strain gauges 3, 4, 7, 8, 11, 12, 15
and 16 are affected by the thrust force Ft. Among
these strain gauges, 3, 7, 11 and 15 are subject to
tensile stress while 4, 8, 12 and 16 are subject to
compressive stress.
The feed force Ff is supported by A and C rings
of the dynamometer as shown in Fig. 4. The strain
gauges to measure the feed force Ff should be
mounted on the outer surfaces of A and C rings
with 45 inclination angle. As shown in Fig. 4,
the strain gauges 1, 2, 5 and 6 are affected by the
feed force Ff. Among these strain gauges, 1 and 5
are subject to tensile stress while 2 and 6 are sub-
ject to compressive stress.
The main cutting force Fc is supported by B and
D rings as seen in Fig. 4. The strain gauges for
measuring the main cutting force Fc are mounted
on rings B and D with 45 inclination angle with
respect to the vertical plane. As shown in Fig. 4,
the strain gauges 9, 10, 13 and 14 are affected by
the main cutting force Fc.
3.6. Dynamometer construction
3.6.1. Mounting of strain gauges on the rings
The rings of dynamometer were manufactured
at CNC machine tools as seen in Fig. 5. The sur-
faces of the rings were ground for better strain
gauge application. Totally 16, strain gauges were
Fig. 5. Manufactured octagonal dynamometer rings.
85
mounted on four octagonal rings. Two strain
gauges were mounted horizontally on to outsides
of each ring at 45 angles. Two more strain gauges,
one inside and the other outside were also
mounted vertically. See Fig. 4.
HBM: LY 11 6/120 type strain gauges recom-
mended for steel specimens and for static or
dynamic loading were utilized. To achieve low
energy dissipation and hence a stable zero setting
for a long time, excitation voltage must be selected
carefully. The range of excitation voltage for a
thick steel mounting surface may be obtained from
the relation [16]
qffiffiffiffiffiffiffiffiffiffiffiffiffi
V in ¼ 2 RP 0g Ag
in which R is the gauge resistance in ohms, P 0g is
the power density in the gauge grid (between 2
and 5 kW/m2), and Ag is the active grid area
(6 · 2.8). For convenience, an excitation voltage
of 10 V (calculated between 8 and 12.7 V) was
employed.
3.6.2. Mounting of the dynamometer
The rings of dynamometer were mounted be-
tween two plates by using (Ø4 mm.) pins and
M5 screws. Pins were used in order to prevent
the motion of plates due to clearance, which may
cause the cross-sensitivity during measurements.
The dimensions of plates were 100 · 100 · 12ḿm.
The cutter was placed tightly into the hole of the
front plate and tightened with M8 screws to upper
plate in order to sustain the perpendicularity to the
ring plane (see Fig. 6). The sides of front and rear
plates were covered with 5-mm thick transparent
plastic material in order to prevent the strain
gauges from hot chips and from cutting fluid dur-
ing turning.
The dynamometer was fixed on to the saddle of
lathe in a position where the nose of the cutter tips
was on the same line with chuck centre.
3.7. Dynamometer calibration
3.7.1. Static calibration of the dynamometer
In order to determine the elastic deflection of
ring components and consequently the output
voltage under static load, the dynamometer was
86 S. Yaldız, F. Ünsaçar / Measurement 39 (2006) 80–89
Fig. 6. The photo of designed and developed dynamometer.
calibrated. The calibration was made in three
directions for Ff, Ft, Fc and the output voltages
of millivolt were averaged for each direction. The
loads up to 2000 N · 50 N intervals were applied
and the strain values were recorded for each load
intervals. Thus calibration curves were obtained
to convert the output readings into cutting force
values. Figs. 7–9 shows the calibration curves for
feed force, thrust force and main cutting force
respectively. In order to verify the consistency,
the measurements were repeated three times and
very close values were obtained as seen in Figs.
7–9. The effect of loading in one direction on the
other force components was also examined and
minor fluctuations were observed. These effects
were small enough to be ignored. The dynamome-
ter was run idle for 5 min before each calibration
tests as it was ready for measurement in order to
determine the consistency.
Fig. 7. Calibration curve and cross-sensitivity for feed force Ff.
Fig. 8. Calibration curve and cross-sensitivity for thrust force
Ft.
Fig. 9. Calibration curve and cross-sensitivity for main cutting
force Fc.
3.7.2. Dynamic calibration of the dynamometer
The natural frequency of the dynamometer
determines its general dynamic stiffness. In order
that the recorded force is not influenced by the dy-
namic response of the dynamometer, its natural
frequency must be higher than the frequency of
exciting vibration [3]. The natural frequency of
the dynamometer is determined accurately by
setting the dynamometer into vibration and by
measuring its response using accelerometer and
oscilloscope. So, the developed dynamometer, the
dynamic cutting force within the time domain
and frequency domain were recorded while the
machine was running as idle and during the cutting
operation as shown in Fig. 10.
3.8. The dynamometer testing
3.8.1. Linearity test
In order to test the dynamometer for linearity,
approximately 80% of maximum load (3500 N)
was applied on it. The dynamometer outputs and
 S. Yaldız, F. Ünsaçar / Measurement 39 (2006) 80–89 87

Fig. 10. Dynamic cutting force within the time domain and frequency domain.

calibration values obtained are shown in Table 2. fitted symmetrically to the ring axes and if the strain
The percentage error of Ff, Ft and Fc were calcu- rings are not mounted in the direction of measured
lated as 1.3%, 1.4% and 1.2% respectively. These force axes. When the dynamometer tested in X
errors seem to be acceptable for the dynamometer direction, the cross-sensitivity for Y and Z direc-
that will be used in intermittent cutting operations. tion was calculated as 0.18% and 0.7%. While the
test were being carried out on Y and Z direction,
3.8.2. Cross-sensitivity test
The cross-sensitivity can be expressed as the
strain measured on axes which is normal to the Table 3
main axes. It is desired that dynamometers must The results of cross-sensitivity test
not be completely insensitive to the cross-strain. Axes Load (N) Output-e (digital) Average error (%)
It is possible to measure the cutting forces inde- X Y Z X Y Z
pendently and accurately as long as the cross-
Ff 2000 278 5 2 0.18 0.7
sensitivity is small. The strain errors will be less if Ft 2000 8 239 1.3 0.33 0.5
this effect is within an acceptable range. These Fc 2000 16 3 173 0.92 0.17
errors can arise because the strain gauges are not

Table 2 Table 4
The results of linearity test The results of eccentricity test
Axes Load Output-e Calibration Error Axes Load e = 0 mm e = 50 mm (%) Output
(N) (mV) value-e (mV) (%) (N) (mV) (mV) error
Ff 2800 149.6 151.6 1.3 Ff 1000 119 118
0.8
Ft 2800 147.9 145.8 1.4 Ft 1000 122 120
0.16
Fc 3500 93.9 95.06 1.2 Fc 1000 82 81
0.12
88 S. Yaldız, F. Ünsaçar / Measurement 39 (2006) 80–89
Table 5
The results of performance test
Axes e (mV) F (N)
X 19.83 300
Y 16.20 280
Z 34.60 900
the cross-sensitivity was calculated as 0.33% and
0.5%, and 0.92% and 0.17% respectively as shown
in Table 3.
3.8.3. Eccentricity test
In a three-component dynamometer, the ap-
plied load within the square outlined by axes of
rings must always give same output value. To test
this condition, the dynamometer was subject to
eccentricity test. In order to test the dependence
of outputs of gauges affected by application point
of Ff, Ft and Fc forces, the force (1000 N) was ap-
plied to the dynamometer at centre and at e = 50
mm distance from the calibration point. The per-
centage of output errors for Ff, Ft and Fc were
found as
0.8%,
0.16% and
0.12% as shown
in Table 4.
3.8.4. Performance test
For this test, the dynamometer axes were kept
neither horizontal nor vertical position, but in-
clined 5 and 1000 N load was applied from the
point of zero eccentricity. The outputs (ex, ey,
ez
le) were measured and percentage of output
error was calculated as 0.2%. The performance test
results are given in Table 5.
4. Conclusion
In this study, strain gauge based dynamometer
has been designed and developed. It has been de-
vised and connected with necessary data acquisi-
tion system consisting of hardware and software.
Dynamometer can measure three perpendicular
cutting force components simultaneously during
turning and the measured numerical values can
be stored in computer by data acquisition system.
This dynamometer was designed to measure up
to 3500 N maximum force and the sensitivity of
F (N) % Output error
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
F ¼ F 2x þ F 2y þ F 2z Accuracy = 989.14/1000 = 0.98
F = 989.14 N Error = 10.86/1000 = 0.02
system is ±5 N. In order to determine accuracy,
the dynamometer was calibrated statically and
dynamically and subjected to linearity test, cross-
sensitivity test, eccentricity test and performance
test. The values of cross-sensitivity of the dyna-
mometer for the three directions were calculated
in the range of 0.17–0.92%. Dynamometer can be
assumed as reliable as this small value can be
neglected. In turning operations, appropriate
results were obtained in cutting force measure-
ments. The obtained results of machining tests per-
formed at different cutting parameters shows that
the dynamometer can be used reliably to measure
cutting forces. Although it was designed primarily
for turning, it can be used for milling, drilling, etc.
Acknowledgement
This experimental study was supported by
Coordination Office to Scientific Research Projects
of Selcuk University. The authors would like to
thank to Coordination Office to Scientific Re-
search Projects of Selcuk University for providing
the financial support to accomplish the project.
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