302530 A- Machining Science

and Technology
Unit Number: 4
Unit Name: Measurement of Cutting Forces
Unit Outcomes: CO4
ANALYSE cutting forces.

Dr. D. Y. Patil Institute of Technology

Reasons for measuring cutting forces (need of measurement of cutting forces)
• The measurement of cutting forces is crucial in various machining operations,
particularly in metal cutting processes such as turning, milling, drilling, and grinding.
The cutting forces generated during these processes provide valuable information
about the efficiency, performance, and quality of the machining operation.
• Process Optimization: Measurement of cutting forces helps in optimizing the
machining process. By understanding the forces acting on the cutting tool, engineers
and machinists can adjust machining parameters such as cutting speed, feed rate, and
depth of cut to achieve optimal tool life, surface finish, and material removal rates.
Fine-tuning these parameters based on cutting force data can lead to improved
productivity, reduced tool wear, and enhanced machining efficiency.

Dr. D. Y. Patil Institute of Technology

Reasons for measuring cutting forces (need of measurement of cutting forces)
• Tool Wear and Tool Life Prediction: Cutting forces can provide insights into the
wear behavior of cutting tools. As a tool wears out during machining, the cutting
forces tend to increase. By monitoring the cutting forces, machinists can estimate
the tool wear and predict the remaining useful life of the tool. This allows for
proactive tool replacement or re-sharpening, preventing unexpected tool failure
and minimizing downtime.
• Detection of Machining Anomalies: Unusual or sudden changes in cutting forces
can indicate machining anomalies or problems such as tool breakage, workpiece
irregularities, improper chip evacuation, or machine tool vibration. By
continuously monitoring cutting forces, operators can identify these issues in real-
time and take corrective actions to prevent further damage or scrap production.
Early detection of anomalies can save time, costs, and potential equipment
damage.
Dr. D. Y. Patil Institute of Technology
Reasons for measuring cutting forces (need of measurement of cutting forces)
• Quality Assurance: Cutting forces can serve as a measure of machining quality.
Inconsistent or excessive cutting forces can result in poor surface finish,
dimensional inaccuracies, and part distortions. By monitoring and controlling
cutting forces within acceptable ranges, manufacturers can ensure consistent part
quality and adherence to specified tolerances.
• Research and Development: Measurement of cutting forces plays a significant
role in research and development activities related to machining processes and
tool materials. It provides valuable data for analyzing the performance of
different tool geometries, coatings, cutting parameters, and materials. By
understanding the relationship between cutting forces and process variables,
researchers can optimize tool designs and develop innovative machining
techniques. quality.
Dr. D. Y. Patil Institute of Technology
Reasons for measuring cutting forces (need of measurement of cutting forces)
• Process Monitoring and Control: Real-time measurement and monitoring of
cutting forces enable process control and adaptive machining strategies. By
integrating force sensors into the machining setup, automated systems can
dynamically adjust cutting parameters based on the measured forces. This
facilitates adaptive control, optimizing the machining process in response to
variations in workpiece material, tool wear, or other factors, resulting in
improved efficiency and part quality.

Dr. D. Y. Patil Institute of Technology

Requirements of Dynamometer
• Power Capacity: The dynamometer should be capable of handling the power output of the
system under test. The power capacity is determined by the maximum torque and rotational
speed that the dynamometer can withstand without mechanical failure. It is important to
consider both continuous power and peak power requirements to ensure the dynamometer
is suitable for the intended application.
• Torque Measurement Range and Accuracy: Dynamometers should accurately measure
torque generated by the system under test. The torque measurement range should cover the
expected torque output of the system. The accuracy of torque measurement is crucial for
reliable data acquisition and performance evaluation. Higher accuracy is usually achieved
through the use of precision load cells or strain gauges.
• Environmental Considerations: Dynamometers should be designed to operate under the
specific environmental conditions of the testing facility. Factors to consider include
temperature, humidity, vibration, and dust levels. Special enclosures or cooling systems
may be required to maintain optimal performance and protect sensitive components.
Dr. D. Y. Patil Institute of Technology
Requirements of Dynamometer
• Speed Measurement and Control: Dynamometers require precise measurement and
control of rotational speed. This is typically achieved using speed sensors, such as
encoders or tachometers, to provide accurate speed feedback to the dynamometer
control system. The control system should be able to maintain the desired speed set
points within specified tolerances.
• Response Time: The dynamometer should have a fast response time to capture rapid
changes in torque and speed accurately. Quick response is crucial for applications that
involve transient operations, such as engine acceleration or deceleration testing.
• Safety Features: Safety is paramount when working with high-power rotating
machinery. Dynamometers should be equipped with safety features to protect operators
and equipment. This may include emergency stop buttons, overload protection
mechanisms, and safety interlocks to prevent unintended operation or catastrophic
failures.
Dr. D. Y. Patil Institute of Technology
Requirements of Dynamometer
• Data Acquisition and Control System: A reliable data acquisition and control system is
essential for accurate measurement and control of the dynamometer. It should be capable of
capturing and analyzing real-time data, including torque, speed, power, and other relevant
parameters. The system should offer user-friendly interfaces for data visualization and
analysis.
• Maintenance and Serviceability: Dynamometers should be designed for ease of
maintenance and serviceability. This includes access to critical components, availability of
spare parts, and clear documentation for troubleshooting and repair. Regular maintenance
schedules should be established to ensure optimal performance and longevity of the
dynamometer.
• Cost and Budget: The cost of the dynamometer should be considered in relation to the
desired features and performance requirements. A balance should be struck between the
budgetary constraints and the necessary capabilities of the dynamometer to meet the testing
objectives effectively.
Dr. D. Y. Patil Institute of Technology
Classification of cutting force dynamometers
1. Mechanical type dynamometer
2. Hydraulic type dynamometer
3. Pneumatic type dynamometer
4. Optical type dynamometer
5. Inductance type dynamometer
6. Piezoelectric type dynamometer
7. Strain gage type dynamometer

Dr. D. Y. Patil Institute of Technology

Mechanical type dynamometer
• A dynamometer is a device used for measuring the torque and brake power
required to operate a driven machine.
Dynamometers can be broadly classified into two types. They are:
• Power Absorption Dynamometers: Power Absorption dynamometers measure
and absorb the power output of the engine to which they are coupled. The power
absorbed is usually dissipated as heat by some means.
Examples of power absorption dynamometers are Prony brake
dynamometer, Rope brake dynamometer, Eddy current dynamometer, Hydraulic
dynamometer, etc.
• Power Transmission Dynamometers: In power transmission dynamometers
the power is transmitted to the load coupled to the engine after it is indicated on
some scale. These are also called torque meters.

Dr. D. Y. Patil Institute of Technology

Prony Brake Dynamometer:
Pony Brake is one of the simplest dynamometers for measuring power output
(brake power). It is to attempt to stop the engine using a brake on the flywheel
and measure the weight which an arm attached to the brake will support, as it
tries to rotate with the flywheel.
The Prony brake shown in the above consists of a wooden block, frame, rope,
brake shoes and flywheel. It works on the principle of converting power into
heat by dry friction. Spring-loaded bolts are provided to increase the friction by
tightening the wooden block.

Dr. D. Y. Patil Institute of Technology

• . Rope Brake Dynamometer:
• The rope brake as shown in below figure is another device for measuring brake
power of an engine. It consists of some turns of rope wound around the
rotating drum attached to the output shaft. One side of the rope is connected to a
spring balance and the other side to a loading device. The power is absorbed in
friction between the rope and the drum. Therefore drum in rope brake requires
cooling.

Dr. D. Y. Patil Institute of Technology

• Absorption Dynamometers:
• Transmission dynamometers are also called torque meters. They mostly consist
of a set of strain-gauges fixed on the rotating shaft and the torque is measured by
the angular deformation of the shaft which is indicated as the strain the of the
strain gauge. A four arm bridge is used to reduce the effect of temperature, and
the gauges are arranged in pairs such that the effect of axial or transverse load on
the strain gauges is avoided.

Dr. D. Y. Patil Institute of Technology

Strain gauge type dynamometers.
Strain gauge type dynamometers are a type of force measuring devices that utilize
strain gauges as the primary sensing element. These dynamometers are
commonly used in various applications where accurate and reliable force
measurements are required. The working principle of strain gauge type
dynamometers is based on the strain-variation relationship of the strain gauge
when subjected to an applied force.

Dr. D. Y. Patil Institute of Technology

Strain gauge type dynamometers.
• The working principle of strain gauge type dynamometers is
based on the relationship between the applied force and the
resulting strain in the strain gauge. When a force is applied to
the dynamometer, the strain gauge deforms, leading to a
change in its electrical resistance. This change in resistance is
proportional to the applied force and can be measured using
various techniques.
• Strain gauges are designed to have a high gauge factor, which
is a measure of the sensitivity of the gauge to strain. The gauge
factor determines the extent of resistance change per unit
strain. By measuring the change in resistance, the strain gauge
type dynamometer can accurately determine the applied force.

Dr. D. Y. Patil Institute of Technology

Lathe/Milling/Drilling Tool Dynamometer

Dr. D. Y. Patil Institute of Technology

Lathe/Milling/Drilling Tool Dynamometer
Construction-
A lathe tool dynamometer consists of the following main components:
Sensor Unit: The sensor unit is the primary component of the dynamometer and is
responsible for measuring the cutting forces. It typically includes strain gauges or load
cells strategically positioned to measure the forces acting on the lathe tool during the
machining process. The sensor unit is designed to be rigid and robust to withstand the
machining forces.
Clamping Mechanism: The clamping mechanism securely holds the lathe tool in place. It
ensures that the cutting forces are transmitted accurately to the sensor unit for
measurement. The clamping mechanism is designed to provide a stable and rigid setup to
minimize any vibration or deflection during machining.
Signal Conditioning Circuitry: The signal conditioning circuitry is responsible for
processing the signals from the strain gauges or load cells and converting them into usable
electrical signals. It may include amplifiers, filters, and analog-to-digital converters to
ensure accurate and reliable force measurements.
Dr. D. Y. Patil Institute of Technology
Lathe/Milling/Drilling Tool Dynamometer
Working :
The lathe tool dynamometer operates based on the principle of strain measurement. As the
lathe tool engages with the workpiece and performs cutting operations, it experiences
cutting forces in different directions, such as axial, radial, and tangential forces.
The strain gauges or load cells integrated into the sensor unit detect the deformation or
strain caused by these cutting forces. The strain is converted into an electrical signal
proportional to the force magnitude. The signals from the strain gauges or load cells are
then conditioned, amplified, and converted into digital form for further analysis and
processing.

Dr. D. Y. Patil Institute of Technology

Lathe/Milling/Drilling Tool Dynamometer
Applications :
Cutting Force Optimization: Lathe tool dynamometers provide real-time feedback on
cutting forces during turning operations.
Tool Wear Monitoring: By continuously measuring the cutting forces, the lathe tool
dynamometer enables the monitoring of tool wear.
Process Development and Research: Lathe tool dynamometers are valuable tools for
process development and research in turning operations.
Quality Assurance: Lathe tool dynamometers are used in quality assurance to ensure
consistent machining quality.
Education and Training: Lathe tool dynamometers are utilized in educational institutions
and training centers to teach and demonstrate turning operations.

Dr. D. Y. Patil Institute of Technology