A New Static Calibration Methodology for Strain Gage Integrated Dynamometers

Abstract

This study attempted to produce a new static calibration methodology for strain gage integrated dynamometers, which can measure three cutting force components simultaneously. In this framework, a dynamometer and two calibrators were designed and manufactured. The standard weights were transmitted to the dynamometer via the calibrators, and the output voltages for the loading/unloading conditions (mV/V) were measured and recorded. Suitable calibration data sets were selected statistically from the output voltages, and the cross interactions between the force components were investigated. F<inf>r</inf> had a cross effect on F<inf>f</inf> and F<inf>c</inf> as a decrease in trend because of the bending moment. The detected F<inf>r</inf> cross interaction resulting from the bending moment was analyzed with the help of the finite element method. Second, a mathematical approach was defined to eliminate the cross interaction, and the conversion equation for each force component was determined by linear regression. A large-scale calibration diagram was plotted both to estimate the force components better and to clearly show the F<inf>r</inf> cross effect on F<inf>f</inf> and F<inf>c</inf>. This methodology could enable the manufacture of a strain gage integrated dynamometer that can measure the cutting force components for turning operations with greater precision. © 2016, Springer-Verlag London.