Stationary dynamometer for measuring cutting forces

Stationary dynamometers measure cutting forces in processes ranging from micromachining to heavy machining

Piezoelectric measurement technology is also the basis for our stationary dynamometers. Their design makes them especially suitable for measuring the cutting forces that act on the workpiece in applications where workpieces are mounted directly on machining tables. The benefit: these dynamometers can be used universally on machines with a wide variety of spindle interfaces. They have proven to be highly versatile tools, especially for use in research and development. 

For lathes, we offer a special series of products that allow measurement of cutting forces on the tool side. For this purpose, suitable adapters can be used to mount selected dynamometers between the tool and the turret. This allows users to combine many different turning tools and machines with the dynamometers.

Most stationary dynamometers are structured as force measurement platforms with a measuring plate mounted on several 3-component force sensors. This structure makes the dynamometer highly rigid and tilt-resistant, and also ensures high natural frequencies. Thanks to these advantages, dynamic measurements of cutting forces are possible in the three orthogonal directions, so complex machining processes can be analyzed with precision down to each individual edge engagement – even at very high spindle speeds. This is why stationary dynamometers from Kistler are deployed in a vast range of applications – from micromachining through to heavy machining.

Typical applications for dynamometers.

High insulating connection cables for dynamometer.

From micromachining to heavy machining – standard dynamometers: 9257B, 9255C, 9253B22/23, 9272 and 9366CC

Our stationary dynamometers for universal use correspond to 3-component measuring platforms based on four piezoelectric sensors. They can handle cutting force measurements of up to 60 kN, and Kistler offers cover plates with dimensions of up to 400x600 mm; the plate size will vary depending on the measuring range. Dynamometers 9257B, 9255C, 9253B22/23 and 9366C are particularly suitable for milling and grinding operations. On the other hand, the strengths of the 4-component dynamometer (9272) come into play for integrated measurement of moments during drilling operations.

For universal use: the handy table-mounted 9257B multicomponent dynamometer offers a measuring range of up to 10 kN – making it ideal for many applications. 

Robust: the 9255C is one of the largest dynamometers in Kistler's range – and with its robust platform, it is optimized for heavy machining. It can measure cutting forces of up to 60 kN. This dynamometer also gives you the option of preloading above the center of the four sensors to make optimal use of the natural frequency.

Large: stationary dynamometer 9253B22/23 features a cover plate measuring 400x600 mm, so larger workpieces can also be mounted safely. The measuring platform is mounted on the machine tool table through the center of the four feet. Although the base plate is used on all other stationary dynamometers, it is omitted in this case.

The drilling process specialist: the 9272 4-component dynamometer is the only stationary dynamometer that measures the cutting forces acting in the three orthogonal directions as well as moment Mz directly in the center of the platform. This makes it the ideal instrument to optimize drilling processes.

Customized solutions for individual requirements: the 9366C kit from Kistler offers you a ready-to-connect, preloaded and calibrated multicomponent construction kit so you can build your own multicomponent measuring platforms to meet your specific requirements. The sensors can be moved freely on the table. This kit allows you to implement clamping solutions with cover plate sizes ranging from 300x300 mm to 900x900 mm.

From micromachining to heavy machining – temperature-compensated dynamometers: 9109AA, 9119AA1/2, 9129AA and 9139AA

Piezoelectric measurement technology is very well suited to meet the demanding requirements that highly dynamic machining sets in terms of the sensitivity and dynamics of the signals to be captured. The thermal energy given off during the cutting process usually causes undesirable signal drift. This effect is particularly noticeable in applications with very high spindle speeds and material removal rates. A stationary dynamometer with horizontal preload largely eliminates the negative influences of heat generation, so drift is minimized. This allows accurate measurements of processes involving high levels of heat generation and/or thermal differences.

Kistler offers temperature-compensated dynamometers for applications ranging from micromachining through to heavy machining. Thanks to their optimized rigidity and mass, these dynamometers attain exceptionally high natural frequencies. All the multicomponent dynamometers are suitable for milling, drilling and grinding operations, among many others. For the 9119AA2 and 9129AA, Kistler also offers special adapters for tool-side force measurements during turning operations.

MicroDyn: thanks to its high rigidity and a natural frequency of more than 15 kHz, the 9109AA is our most favored solution to overcome the special challenges of micromachining. These characteristics enable it to analyze forces in cutting processes at speeds of up to 160,000 rpm across measuring ranges in the spectrum from less than 1 N to 500 N. The special design of this device also allows users to calculate the moment Mz in the center of the dynamometer, based on the individual force components.

MiniDyn: the MiniDyn series comprises the 9119AA1 and 9119AA2 versions. The 9119AA1, which attains natural frequencies of over 6 kHz, is suitable for high-precision machining with forces of less than 1 N to 4 kN, at speeds of up to 60,000 rpm. The 9119AA2 features a somewhat larger clamping surface (107x80 mm) as well as natural frequencies in excess of 4 kHz in all three directions. This allows analysis of machining operations at speeds of up to 40,000 rpm. The 9119AA2 is suitable for table mounting and can also be used as a modular system with adapters for mounting on lathes.

MidiDyn: the MidiDyn 9129AA multicomponent dynamometer is Kistler's best-selling dynamometer model. With a wide measuring range from –10 to 10 kN and a clamping area of 150x107 mm, this is an all-rounder designed for table mounting or for use as a modular system that can be installed on turning turrets.

MaxiDyn: the compact and robust 9139AA multicomponent dynamometer features a wide measuring range (up to 30 kN) to ensure precise measurements of cutting forces in heavy-duty machining processes.

Our temperature-compensated stationary dynamometers (9119AA1/2 and 9129AA) can also be used to measure cutting forces or to analyze and optimize cutting processes in turning operations.

Kistler offers you an extensive choice of standard commercial adapters for every dynamometer, covering all commonly used machine-side and tool-side interfaces (including HSK, VDI, and others).

The appropriate machine adapters make it easy to position the dynamometers directly on the turret head. Then, the tool is placed on the dynamometer with a suitable tool adapter.

Stationary dynamometers are highly versatile

Machining processes can only achieve consistently high product quality combined with cost-efficient operation if there is optimal coordination of machine tools, clamping devices, coolants and materials.

Stationary dynamometers from Kistler are deployed in many types of machining to deliver precise, highly dynamic measurements of cutting forces. The data obtained provides the basis for optimizing tools and machining processes:

Technical University Dortmund

Technical University Dortmund

In university-level R&D work aimed (for example) at developing new tools and cutting strategies for micromachining.

Blaser Swisslube AG

Blaser Swisslube AG

 

 

To develop and evaluate coolants – every coolant technology involves different progressions of cutting forces: high-precision measurement data and informative force curves provide the basis for adapting coolants directly to specific materials and processes.

Polytechnic University of Milan

Polytechnic University of Milan

In materials research – for example, to develop new types of materials that can be used in innovative cutting tools: depending on the choice of material (metal, ceramic, etc.), different process characteristics can be achieved when the cutting tool is use.

MITIS

MITIS

To assess machines and production equipment – reliable measurement data obtained from cutting force analyses plays a key part in the development and optimization of systems for vibration-assisted drilling. Systems of this sort are used in some types of heavy-duty cutting where chip breaking has a decisive influence on the efficiency of the process.

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