Design and experimental set-up of a hybrid dynamometer applied to a fourth axis of the vertical machining center
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ORIGINAL ARTICLE
Design and experimental set-up of a hybrid dynamometer applied to a fourth axis of the vertical machining center Adilson José de Oliveira 1 & Dávila Moreira Lopes Silva 1 & Jefferson Igor Duarte da Silva 2 & Zilda de Castro Silveira 3 Received: 17 May 2020 / Accepted: 25 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract This paper describes a functional prototype of a hybrid dynamometer, based on strain gauges, designed to be clamped on the fourth axis of a vertical machining center, to measure axial force and torque. This study is described in five steps: design, engineering analysis, instrumentation, static calibration, and natural frequency evaluation. In order to provide reliability with regard to the signal acquisition, a small wireless data transfer system was implemented. This system was developed for signal conditioning and amplification associated with a transmission module integrated to a dynamometer. Furthermore, a wireless receiver module and data processing codes were used to measure mechanical loads. The results indicate that the design is consistent with the operating requirements that the dynamometer needs to be able withstand axial force and torque up to 1 kN and 30 Nm, respectively. The calibration results indicated that the sensing elements operate in the elastic regime for the described loading range, due to the linear trend of calculated R2 values greater than 0.99. The wireless system approach allowed data transfer up to a distance of 3 m. The minimal natural vibration frequency of the device is 602.2 Hz. Keywords Dynamometer . Strain gauges . Engineering design . Instrumentation . Data acquisition . Telemetry
1 Introduction In machining processes, information on mechanical loads is needed to investigate the progress of wear or damage on the cutting edges, aiming to optimize the cutting parameters or to develop innovative cutting strategies. Thus, this information is essential in order to describe, monitor, and improve the performance on the manufacturing shop floor. Dynamometers are designed to measure the components of the cutting force and are usually classified as stationary or rotary, according to the relative movement between the device and the machined material. Stationary dynamometers are normally mounted on the * Adilson José de Oliveira [email protected] 1
Department of Mechanical Engineering, Technology Center, Federal University of Rio Grande do Norte, 3000 Sen. Salgado Filho Avenue, Lagoa Nova Campus, Natal, RN, Brazil
2
Department of Informatics and Applied Mathematics, Exact and Earth Sciences Center, Federal University of Rio Grande do Norte, Natal, RN, Brazil
3
Department of Mechanical Engineering, Engineering School of São Carlos, University of São Paulo, São Carlos, SP, Brazil
machine tool table, while rotary dynamometers are mounted in the machine spindle. Some versions of dynamometers, based on different measurement principles, have been proposed and developed to comply with design requirements and the operating con
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