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Technical Briefs

Design, Manufacturing, and Calibration Process of One Piece Lathe Dynamometer for Measurement in Two Axes

[+] Author and Article Information
Ergun Ateş

Faculty of Engineering and Architecture,
Department of Mechanical Engineering,
The University of Balıkesir,
Balıkesir 10145, Turkey
e-mail: ergunates@balikesir.edu.tr

Kadir Aztekin

Institute of Sciences,
Division of Mechanical Engineering,
The University of Balıkesir,
Balıkesir 10145, Turkey
e-mail: kadiraztekin@bau.edu.tr

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received April 6, 2012; final manuscript received May 4, 2013; published online July 17, 2013. Assoc. Editor: Suhas Joshi.

J. Manuf. Sci. Eng 135(4), 044501 (Jul 17, 2013) (5 pages) Paper No: MANU-12-1106; doi: 10.1115/1.4024532 History: Received April 06, 2012; Revised May 04, 2013; Accepted May 07, 2013

Many pieces in structure of a dynamometer may negatively affect the accuracy of the measurements since each piece may display a different strain and stress depending on its material and construction. A one piece dynamometer has been designed to eliminate these negative effects and to facilitate reliable force measurements. A dynamometer that its dimensions were confirmed following strength calculations was manufactured and calibrated in two different ways. The first one was multipoint calibration method in which certain loads were applied to the dynamometer and strain values corresponding to these loads were matched. The second calibration method was implemented using Kistler dynamometer that its results are accepted to be accurate by everyone and it was based on equivalency of force values resulted from work piece processing and force values resulting from machining work pieces with the same parameters to the manufactured dynamometer. The manufactured dynamometer was capable of measuring cutting forces and feeding forces.

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Figures

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Fig. 1

Designed (a) and manufactured (b) dynamometer

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Fig. 2

Cabled dynamometer with identified strain gauge that its strain gauge safeguard, tool holder, and tool are attached (in the figure: 1- dynamometer, 2- strain gauge, 3- cable, 4- container, 5- tool holder, and 6- tool)

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Fig. 3

Calibration apparatus (a), cutting force calibration (b), and feeding force calibration (c) (in the figure: 1- feeding force calibration table, 2- cutting force calibration table, 3- load frame, 4- load heading, 5- tool holder, and 6- dynamometer)

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Fig. 4

Machining using (DM), the manufactured dynamometer (a) and Kistler-9257B (b)

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Fig. 5

Variation of cutting and feeding forces with microstrain for DM dynamometer calibration

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Fig. 6

Variation of the cutting (Fc) and feeding (Fv) forces based on feeding in machining using Kistler dynamometer and variation of the strain value based on feeding in machining using DM dynamometer

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