The main focus of this work was the design and development of a cross-beam force transducer for use in the construction of a tri-axial dynamometer. This dynamometer would be able to measure the cutting force along all three axes simultaneously during turning operations. The force transducer was built on the concept of the Maltese cross-beam, but it had been modified and improved so that it had a higher sensitivity and reduced the amount of interference error or cross-talk error that it produced. An investigation into the distribution of strain, as well as the determination of sensor locations within the transducer construction was carried out by means of finite element analysis. In order to develop a prototype of a turning dynamometer, a number of piezoresistive strain gauges were utilized in the transducer. In order to determine sensitivity, linearity, hysteresis, and repeatability, calibration tests were performed in three directions that were perpendicular to one another. To investigate the dynamic properties and capabilities of the dynamometer for use in turning applications, both modal analysis and actual turning tests were performed. The results of the experiments demonstrated that the newly developed turning dynamometer is a realistic approach for measuring cutting force in machining without reliability and accuracy.
Keywords: cross-beam force transducer; cutting force measurement; fine turning process; piezoresistive strain gauge; tri-axial turning dynamometer.