P17665: Rotating Dynamometer for Cutting Tools
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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

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!