Cross-sensitivity control in a novel four-component milling dynamometer for simultaneous measurement of tri-axial forces and torque

Abstract

In the present study, a strain gauge-based low-priced dynamometer and a customized data acquisition system are developed to simultaneously measure torque and tri-axial cutting forces in end-milling and drilling operations. This design includes 24 strain gauges bonded on four octagonal rings. To achieve the utmost sensitivity and overcome the cross-talk among the torque and components with gauges located at similar locations, finite element analyses have been practiced. These analyses determined the best composition of the gauges to attain the desired results. A model is then used to describe the system mathematically, and modal analyses have been conducted to estimate the dynamometer's working range. Face milling operations have been run to test the dynamometer's efficiency. The designed dynamometer was accredited by a commercially available dynamometer as a reliable and affordable instrument to be used in low to medium-speed milling processes and can be adopted by industries and laboratories with limited resources.