P17665: Rotating Dynamometer for Cutting Tools

/public/

Home

Project Summary	Project Information
For an updated project description, click on the following link for the Project Readiness Package. There is a constant desire for an accurate way to measure and analyze the cutting force of a machine or tool in order to optimize machining processes for tool life. Accurate cutting force measurements are key variables in the optimization processes for cutting, predicting surface roughness, and monitoring tool wear and performance. Currently the customer is in possession of a stationary dynamometer designed for use on a lathe. However, the customer wants to adapt the existing technology for use on a rotating tool in a milling machine or drill press. A specialized toolholder can be inserted into the machine with internally-mounted strain gauges that can be used to detect deformations within the structure. The strain gauges change resistance as the structure naturally deforms from the cutting process. This resistance can be measured and wirelessly transmitted by a microcontroller to a computer so the customer can analyze the force data. The goal of the project is to develop an accurate dynamometer to measure cutting forces in three dimensions with respect to rotating cutting tools. The dynamometer should be able to accurately collect data when experiencing forces up to 500 N and rotation speeds up to 2000 rpm. The dynamometer should also have an ideal lifespan of 300 hours. An operations manual containing detailed user instructions will also need to be produced. Bridgeport Milling Machine	Project Name Strain Gauge Dynamometer for Cutting Tools Project Number P17665 Project Family Automated Systems and Measurement Start Term 2161 End Term 2165 Faculty Guide Gary Werth, gdwddm@rit.edu Primary Customer and Sponsor Dr. Rui Liu, rleme@rit.edu

Team Members

Team Photo (From left to right): Joseph Amoia, Muhammad Ibraheem, Zac Rubeor, Elbert Heacock, Brian Coren

Team Photo (From left to right): Joseph Amoia, Muhammad Ibraheem, Zac Rubeor, Elbert Heacock, Brian Coren

Member	Major	Role	Contact
Joseph Amoia	Electrical Engineering	Project Manager	jma3587@rit.edu
Brian Coren	Mechanical Engineering	Mechanical Engineering Lead	bcc1493@rit.edu
Elbert Heacock	Mechanical Engineering	Lead Process Engineer	edh8538@rit.edu
Muhammad Ibraheem	Electrical Engineering	Electrical Engineering Lead	mxi6679@rit.edu
Zac Rubeor	Mechanical Engineering	Team Leader	zmr3170@rit.edu

Table of Contents

MSD I & II	MSD I	MSD II
Planning & Execution Project Photos and Videos Imagine RIT	Problem Definition Systems Design Preliminary Detailed Design Detailed Design Gate Review	Build & Test Prep Subsystem Build & Test Integrated System Build & Test Integrated System Build & Test with Customer Demo Customer Handoff & Final Project Documentation

Project Overview

Project	Validation/Analysis	Mechanical Design	Electrical Design	Academic
Project Overview Requirements Flow Customer Requirements Validation Engineering Requirements Validation Performance vs. Engineering Requirements MSD I Project Plan MSD II Project Plan Bill of Materials Purchasing Bill of Materials Risk Risk Graph	Test Plans Full Summary of Testing Calibration Data ANSYS Simulations Initial Feasibility Analysis Mechanical Analysis: Force Equations Deflection Analysis Electrical Analysis: Wheatstone Bridge Circuit Amplifier Circuit Power Consumption	Toolholder Adapter & Toolholder Acceptor CAD/Drawings Measurement Structure CAD/Drawings Housing Drawings Full Assembly CAD/Drawings Deflection Analysis (.xlsx) Force Calculation Values Force Calculation Spreadsheet (.xlsx) Mechanical Assembly Circuitry Placement	High Level Overview Wheatstone Bridge Circuit Amplifier Circuit Program Flow Wiring Diagram Power Calculations Bluetooth Transmission: Sitting Voltage Values Bluetooth Transmission: Packet Loss Test Electrical Assembly Housing Drawings	Mid-Phase Report Updated Mid-Phase Report ImagineRIT Poster Technical Paper Post Mortem Analyses Lessons Learned Feedback and Self Critique Recommendations for Future Work

Acknowledgements

Thank you to Dr. Liu and Gary Werth for all of your help so far!