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The cutting force measurement in a fixturing setup with instrumented locators

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Abstract

Piezo-electric multi-component dynamometers are commonly used for research and development purposes but their application in a real manufacturing environment is rather limited due to various factors. This paper presents a methodology by which the dynamometer can be replaced effectively by six instrumented locators with uniaxial piezo-electric force sensors in a fixturing setup. A system was developed using the output from six uniaxial force sensors, which are positioned around the workpiece to suit the configuration of the workpiece. Experiments were conducted under actual cutting conditions to validate the equations developed and the analysis was performed to correlate the relationship between the forces measured with a piezo-electric Kistler dynamometer and the forces calculated from the output of the instrumented locators. The force values from the dynamometer and the instrumented locators were recorded for a series of end milling tests under different cutting conditions and the accuracy of the model was studied.

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Abbreviations

FAA::

Force exerted by clamp 1

FBB::

Force exerted by clamp 2

FA::

Reaction force on locator 1

FB::

Reaction force on locator 2

FC::

Reaction force on locator 3

FD::

Reaction force on locator 4

FE::

Reaction force on locator 5

FF::

Reaction force on locator 6

F t ::

Cutting force along the X-axis

F f ::

Cutting force along the Y-axis

F a ::

Cutting force along the Z-axis

f x ::

Subscript denoting the component of friction force along the X-axis, for the respective force acting on the workpiece

f y ::

Subscript denoting the component of friction force along the Y-axis, for the respective force acting on the workpiece

f z ::

Subscript denoting the component of friction force along the Z-axis, for the respective force acting on the workpiece

T 1::

Cutting torque about the Z-axis

T 2::

Cutting torque about the X-axis

T 3::

Cutting torque about the Y-axis

x i ::

Geometric parameter of the workpiece configuration along the X-axis, where i=1, 2, 3, 4

y i ::

Geometric parameter of the workpiece configuration along the Y-axis, where i=1, 2, 3, 4

z i ::

Geometric parameter of the workpiece configuration along the Z-axis, where i=1, 2, 3

a x ::

Axial depth of cut

a r ::

Radial depth of cut

r s ::

Rotational speed

F x ::

Force along the X-axis as measured by the dynamometer

F y ::

Force along the Y-axis as measured by the dynamometer

F z ::

Force along the Z-axis as measured by the dynamometer

F x *::

Calculated value of the force along the X-axis

F y *::

Calculated value of the force along the Y-axis

F z *::

Calculated value of the force along the Z-axis

e x ::

Error between the directly measured cutting force in the X-direction and the calculated force acting in the same direction

e y ::

Error between the directly measured cutting force in the Y-direction and the calculated force acting in the same direction

e z ::

Error between the directly measured cutting force in the Z-direction and the calculated force acting in the same direction

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Authors and Affiliations

  1. Department of Mechanical Engineering, The National University of Singapore, Singapore, Singapore

    R. A. Hameed, M. A. Mannan & A. Y. C. Nee

Authors
  1. R. A. Hameed
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  2. M. A. Mannan
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  3. A. Y. C. Nee
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Correspondence to R. A. Hameed.

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Hameed, R.A., Mannan, M.A. & Nee, A.Y.C. The cutting force measurement in a fixturing setup with instrumented locators. Int J Adv Manuf Technol 23, 783–793 (2004). https://doi.org/10.1007/s00170-003-1655-5

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  • DOI: https://doi.org/10.1007/s00170-003-1655-5

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