1

DESIGN, DEVELOPMENT AND TESTING OF A TURNING DYNAMOMETER

FOR CUTTING FORCE MEASUREMENT
Sleyman Yaldz
a*
, Faruk nsaar
a

Mechanical Department, Technical Science College, Seluk University, 42031, Konya, Turkey

Abstract
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 developed. The orientation of octagonal rings and strain gauge locations has
been determined to maximize sensitivity and to minimize cross-sensitivity. The developed
dynamometer is connected to a data acquisition system. Cutting force signals were captured
and transformed into numerical form and processed using a data acquisition system
consisting of necessary hardware and software running on MS-Windows based personal
computer. The obtained results of machining tests performed at different cutting parameters
showed that the dynamometer could be used reliably to measure cutting forces. Although
the dynamometer was developed primarily for turning operations, it can be used to measure
cutting forces during nearly all machining operations (milling, drilling, etc.).
Keywords: Dynamometer; Strain gauge; Data acquisition
1. Introduction
The importance of monitoring the cutting force in turning has been well recognized in
machine tool communities. In particular, Sukvittayawong and Inasaki [1], Tlusty and

*
Corresponding author. Tel.: +90-332-223 2347; Fax: +90-332-2410185.
E-mail address: syaldiz@selcuk.edu.tr (S. Yaldz)



2
Andrews [2] and Weck [3] pointed out that on-line and real-time information of the normal
cutting force is closely related to the tool wear prediction, breakage detection or other
malfunction inspections.
A considerable amount of investigations has been directed towards the prediction and
measurement of cutting forces. That is because the cutting forces generated during metal
cutting have a direct influence on the generation of heat, and thus tool wear, quality of
machined surface and accuracy of the workpiece. Due to the complex tool
configurations/cutting conditions of metal cutting operations and some unknown factors
and stresses, theoretical cutting force calculations failed to produce accurate results.
Therefore, experimental measurement of the cutting forces became unavoidable. For this
purpose, many dynamometers have been developed [4]. In these dynamometers, cutting
force measurement is mainly based on elastic deformation of the materials.
Various studies concerning dynamometer design and construction can be found in the
published 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 inaccuracy and insensitivity in measuring either one or two components
[7].
This study outlines a strain gauge based octagonal-ring type analogue dynamometer
design and prototyping. This dynamometer is capable of measuring 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.


3
2. Materials and method
2.1. Dynamometer
A three-force component analogue dynamometer 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 required can be converted back to analogue. The schematic
representation of the cutting force measurement system is shown in Figure 1.

Figure 1. Schematic representation of experimental set-up
The dynamometer is capable of measuring feed force (F
f
), thrust force (F
t
) and main
cutting force (F
c
) which occurs during turning operations as seen in Figure 2.

Figure 2. Cutting force components which occurs during metal cutting in turning


4
This dynamometer consist of four elastic octagonal rings on which strain gauges were
mounted and necessary connection 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 (Advantech ADAM
3016) are then converted to digital signals and captured by PCL-818H 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.
3. Design and construction of a strain gauge based dynamometer for lathe
3.1. Design criterions and material of dynamometer
Sensitivity, rigidity, elasticity, accuracy, easy calibration, cost and reliability in the
harsh cutting environment have been taken into account in designing the dynamometer.
Dimensions, shape and material of dynamometer are considered to be effective factors on
dynamic properties of the dynamometer.
A dynamometer essentially consists of an important ring element. The rigidity, high
natural frequency, corrosion resistance and high heat conductivity factors were taken into
consideration while selecting the ring materials. Also, deformation under the load should
conform to that of strain gauges [2].
In this study, AISI 4140 steel, which meets above requirements, was selected as the
ring material. The properties of this material are given in Table 1.


5
Table 1. Properties of AISI 4140 steel
Yield strength Modulus of elasticity Poisson ratio Hardness
550-900 N/mm
2
210000 N/mm
2
0.3 217 HB

3.2. Determination of dimensions of the octagonal rings
The thickness t, radius r, and width of the circular 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, b
min
can be taken
as 20 mm to set up the rings securely [8].
The deformation of circular ring under the effect of thrust force F
t
and main cutting
force F
c
separately is shown in Figure 3b and 3c respectively. As long as strain on A and B
where the strain gauges are going to be fixed (Fig 3a) 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 (
c
/F
c
) and stiffness
(F
c
/
c
).

Figure 3. The deformation of circular strain ring under: (a) combined, (b) thrust F
t
, (c) main
cutting F
c
forces.


6
The strain gauges should be placed where the stress concentration has maximum value. The
experiments have shown that good results are obtained for octagonal rings when the
inclined gauges are at points 45
0
from the vertical instead of 39.6
0
required by the circular
ring theory. The strain per unit deflection can be expressed as [8]:

1.09
0.61
/ 1.8
t
t
t t
r r r

=
(1)
where t is the deflection in a radial direction and
t
is the strain due to thrust force F
t
. It is
clear that for maximum sensitivity and rigidity
t
/
t
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. [9] performed a finite element analysis for the elastic behaviour of octagonal rings. They
expressed that the octagonal ring is substantially stiffer 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 mm and 16 mm respectively. Thus, the rate of t/r
(4/16=0.25) provides corresponding sensitivity to stiffness ratio /(/r) for octagonal ring.
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 [10]. Taking into account dimensions as seen in
Figure 4. (b=20 mm; r=16 mm; t=4 mm), elastic strains
t
and
c
due to forces F
t
and F
c
are
calculated according to ring theory by using the following equations [7,8].


7

4
2
1, 09
9.1 10
t
t
F r
x
Ebt

= = (2)

3
2
2,18
1.82 10
c
c
F r
x
Ebt

= = (3)

Figure 4. Octagonal dynamometer ring dimensions
The stress occurring on rings caused by thrust and main cutting forces can be calculated by
placing elastic strain ratio values in Eq. (4, 5) as follows:

2
190.8N/mm
t t
E = = (4)

2
381.5N/mm
c c
E = = (5)
As AISI 4140 steel was used for manufacturing the ring and its yield strength is 550-900
N/mm
2
, the calculated stress values (
t
and
c
) 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
dynamometers natural frequency should be as high as possible. Vibration frequency of the
machine tool is related to the spindle speed of the machine tool. The dynamometer should


8
have natural frequency of at least four times the vibration frequency of the machine tool
[8].
The dynamometer is considered to be a small mass supported by ring elements for
analytical purpose. In order to determine the natural frequency of the dynamometer, the
ring constant of dynamometer should be determined first. The stiffness value for a thin
circular ring is given as in the following equation [8]:

3
3
1.8
t
t
t
F Ebt
K
r
= = (6)
As placing the related values in Eq. (6), the ring constant of the dynamometer is
computed as; 36458 N/mm
t
K = .
The natural frequency of dynamometer, which is assumed to be a small mass supported
by ring elements, can be obtained from the following relation [8]:

1
/
2
d
f K m

= (7)
where; K dynamometer ring constant (N/mm), m dynamometer mass (kg), f
d
dynamometer
natural frequency (rev./s).
The ring mass is 36.43 kg. As placing the related values in Eq. (7), the natural
frequency of dynamometer is computed as f
d
= 159.2 rev/s. To fulfil the requirement as
stated above f
d
> 4 f
m
, the maximum spindle speed of the lathe should be 200 rev/s or 12000
rpm.


9
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
achieving high accuracy in the Wheatstone bridge circuits. The orientation of the strain
gauges on the rings and the position of the rings on the dynamometer are given in Figure 5.

Figure 5. The strain gauges and ring orientation on the dynamometer
The thrust force F
t
are supported by A,B,C and D rings of the dynamometer as shown
in Figure 5. The strain gauges 3,4,7,8,11,12,15 and 16 are affected by the thrust force F
t
.
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 F
f
is supported by A and C rings of the dynamometer as shown in
Figure 5. The strain gauges to measure the feed force F
f
should be mounted on the outer
surfaces of A and C rings with 45
0
inclination angle. As shown in Figure 5, the strain


10
gauges 1, 2, 5 and 6 are affected by the feed force F
f
. Among these strain gauges, 1 and 5
are subject to tensile stress while 2 and 6 are subject to compressive stress.
The main cutting force F
c
is supported by B and D rings as seen in Figure 5. The strain
gauges for measuring the main cutting force F
c
are mounted on rings B and D with 45
0

inclination angle with respect to the vertical plane. As shown in Figure 5, the strain gauges
9, 10, 13 and 14 are affected by the main cutting force F
c
.
3.6. Setting the Wheatstone bridges used in the dynamometer
One full eight active arms bridge arrangement can be arranged for thrust force
measurement and two full four active arms bridge can be arranged for feed force and main
cutting force. Thus, if four active arms are used in one bridge, the bridge output becomes
four times greater than the single arm bridge. Also, full bridge circuit is fully compensated
for any change in resistance due to the temperature.
The strain gauges used have 5% elongation limit on a 6 mm. length. So the maximum
allowed elongation should be less than 6x5%=0.3 mm. The possible elongation could occur
by 3500 N maximum permissible force (F) on a dynamometer and it has 36458 N/mm
rigidity (K) can be calculated as follows:
/
t t t
K F = (8)
/ 0.096mm
t t t
F K = =
Thus the obtained possible elongation value 0.096 mm. is lower than 0.3 mm.
allowable elongation limits.
The strain occurring in the strain gauges can be stated by the following relation [7,11]:


11

0
R L
k
R L

= (9)
where
R Differential resistance due to the voltage ()
R Resistance of the strain gauge prior to application to voltage ()
K Gauge factor (ratio) of strain gauge
L Elongation due to the stress (mm)
L
0
Initial length (mm)
Elongation percent of the strain gauge is stated by L/L
0
= . Therefore, the above
formula can be rewritten as R/R=k. The bridge unbalance V is the ratio of output voltage
UA to input voltage UE of the bridge circuit is given by the following relation [11-14]:

3 1 2 4
1 2 3 4
1
4
R R R R UA
V
UE R R R R
(
= = +
(

(10)
If R
1
= R
2
and R
3
= R
4
the bridge is balanced or, in the other words, the bridge
unbalance is zero. Substituting R/R=k, V is found as;
( )
1 2 3 4
1
4
UA
V k
UE
= = + (11)
where
as
1 2 3 4
= = = = / / (1/ 4)( 4 ) UA UE k = and strain gauge ratio factor is taken
k=2, the output voltage can be reduced to the following definition,
2 UA UE = (12)
If the Eq. (12) giving the output voltage of Wheatstone bridge circuit is applied to
thrust force F
t
, bridge circuit:


12

3 7 15 8 16 11 4 12
3 11 4 12 7 15 8 16
1
4
R R R R R R R R UA
k
UE R R R R R R R R
( | | | | | | | |
= + + + + +
( | | | |
\ . \ . \ . \ .
(13)
is obtained.
As,
( ) ( ) ( ) ( )
3 11 4 12 7 15 8 16
1
4
UA
k
UE
= + + + + + (

(14)

3 11 4 12 7 15 8 16
= = = = = = = =
(15)
for / (1/ 4)( 8 ) UA UE k = and k=2
4 UA UE = (16)
relation is obtained. Or, this relation can be rearranged as

6
4 10 UA UE

= (17)
The principles applied to the thrust force F
t
are also valid for the feed force F
f
. By
using the principles of thrust force F
t
, the feed force F
f
equation can be formed. Again, from
Eq. (12):
2 UA UE =
or can also be written as:

6
2 10 UA UE

= (18)
Similarly, the principles applied for feed force F
f
and thrust force F
t
are also valid for
the main cutting force F
c
. See Figure 6.


13

Figure 6. Wheatstone bridge connections (a) for F
f
, (b) for F
t
and (c) for F
c

3.7. Dynamometer construction
3.7.1. Mounting of strain gauges on the rings
The rings of dynamometer were manufactured at CNC machine tools by using AISI
4140 steel as seen in Figure 7. The surfaces of the rings were ground for better strain gauge
application.

Figure 7. Manufactured octagonal dynamometer rings
Prior to the mounting of the strain gauges, the ring surfaces on which strain gauges
were mounted had been ground and then these surfaces were cleaned by cleaning set
HBM: FC1. Around 30 minutes after the cleaning of the surfaces, the strain gauges were


14
mounted using cold curing rapid adhesive HBM: Z70 and were left for drying for ten
minutes. After curing time, the surfaces of the strain gauges were covered by nitrile rubber
HBM: NG150 to protect against the influence of cutting fluid.
Totally 16, strain gauges were mounted on four octagonal rings. Two strain gauges
were mounted horizontally on to outsides of each ring at 45
0
angles. Two more strain
gauges, one inside and the other outside were also mounted vertically. See Figure 5.
HBM: LY 11 6/120 type strain gauges recommended for steel specimens and for static
or dynamic loading were utilised. 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 [15]:

'
2
in g g
V RP A =

in which R is the gauge resistance in ohms,
'
g
P is the power density in the gauge grid
(between 2 and 5 kW/m
2
), and
g
A is the active grid area (6x2.8 for HBM for LY11 6/120).
For convenience, an excitation voltage of 10 V (calculated between 8 and 12.7 V) was
employed.
3.7.2. Mounting of the dynamometer
The rings of dynamometer were mounted between two plates by using (4 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
100x100x12 mm. 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
Figure 8). The sides of front and rear plates were covered with 5 mm thick transparent


15
plastic material in order to prevent the strain gauges from hot chips and from cutting fluid
during turning.

Figure 8. Designed and developed dynamometer
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.
3.8. Dynamometer calibration
3.8.1. 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 calibrated. The calibration was
made in three directions for F
f
, F
t
, F
c
and the output voltages of milivolt were averaged for
each direction. The loads up to 2000 N by 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. Figure 9,10,11 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 Figure 9,10,11. The effect of loading in one direction on the other force


16
components was also examined and minor fluctuations were observed. These effects were
small enough to be ignored. The dynamometer was run idle for 5 minutes before each
calibration tests as it was ready for measurement in order to determine the consistency.

Fig. 9. Calibration curve and Cross-Sensitivity for feed force F
f


Fig. 10. Calibration curve and Cross-Sensitivity for thrust force F
t


17

Fig. 11. Calibration curve and Cross-Sensitivity for main cutting force F
c
3.8.2. 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 dynamic response of the
dynamometer, its natural frequency must be higher than the frequency of exciting vibration
[16]. 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 Figure 12.


18
-150
-100
-50
0
50
100
1 18 35 52 69 86 103 120 137 154
Number of data
D
y
n
a
m
i
c

c
u
t
t
i
n
g

f
o
r
c
e

(
N
)

0.0001
0.0002
0.0003
0.0004
0.0005
0.0006
0.0007
0.0008
0.0009
0 800
1600 2400 3200
0
0.001
4000

-150
-100
-50
0
50
100
1 16 31 46 61 76 91 106 121 136
Number of data
D
y
n
a
m
i
c

c
u
t
t
i
n
g

f
o
r
c
e

(
N
)
0.0001
0.0002
0.0003
0.0004
0.0005
0.0006
0.0007
0.0008
0.0009
0 800
1600 2400 3200
0
0.001
4000
Figure 12. Dynamic cutting force within the time domain and frequency domain
3.9. The dynamometer testing
3.9.1. Cross-sensitivity test
The cross sensitivity can be expressed as the strain measured on axes which is normal
to the main axes. It is desired that dynamometers must not be completely insensitive to the
cross strain. It is possible to measure the cutting forces independently and accurately as
long as the cross sensitivity is small. The strain errors will be less if this effect is within an
acceptable range. These errors can arise because the strain gauges are not fitted
symmetrically to the ring axes and if the strain rings are not mounted in the direction of
measured force axes. When the dynamometer tested X direction, the cross sensitivity for Y
and Z direction was calculated as 0.18% and 0.7%. While the test were being carried out on


19
Y and Z direction, the cross sensitivity was calculated as 0.33% and 0.5%, and 0.92% and
0.17% respectively as shown in Table 2a.
3.9.2. Eccentricity test
In a three-component dynamometer, the applied 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 F
f
, F
t
and F
c
forces, the force (1000 N) was applied to the
dynamometer at centre and at e=50 mm distance from the calibration point. The percentage
of output errors for F
f
, F
t
and F
c
were found as -0.8%, -0.16% and -0.12% as shown in
Table 2b.
Table 2. The results of tests performed on the dynamometer
a) The results of cross sensitivity test
Axes Load (N) Output (digital) Average error (%)
X Y Z X Y Z
F
f
2000 278 5 2 0.18 0.7
F
t
2000 8 239 1.3 0.33 0.5
F
c
2000 16 3 173 0.92 0.17

b) The results of eccentricity test
Axes Load (N) e=0 mm (mV) e=50 mm (mV) (%) Output error
F
f
1000 119 118 -0.8
F
t
1000 122 120 -0.16
F
c
1000 82 81 -0.12
4. Conclusion
In this study, strain gauge based dynamometer has been designed and developed. It has
been devised and connected with necessary data acquisition system consisting of hardware


20
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 system is 5 N. In order to determine
accuracy, the dynamometer was calibrated statically and dynamically and subjected to
cross-sensitivity test and eccentricity test. The values of cross sensitivity of the
dynamometer 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 measurements. The obtained
results of machining tests performed 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.
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[4] eker U, Kurt A, ifti I. Design and construction of a dynamometer for measurement
of cutting forces during machining with linear motion, Mat. Des. 2002; 23: 355360.


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