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Lab Report on
Force measurement in a shaper machine
using dynamometer

Submitted by

Submitted To

Sanatan Choudhury

Dr. Abhay Sharma

Me15Mtech11015

Contents:

1. Name of the Experiment.3

2. Objective.3
3. Introduction..3
4. Specimen and equipment..5
5. Working Principle.5
6. About Machine..6
7. Procedure..8
8. Testing.9
9. Result9
10.Conclusion.10
11.Points to Remember..10

Name of the Experiment:

Measurement of different forces in a shaper machine using tool dynamometer.

Objective:
To measure the forces of machining in a shaper using machine tool dynamometer.
To study the effect of different machining parameters on forces.

Introduction:
Machine tools are kind of machines on which metal cutting or metal forming processes
are carried out.
Material removal is essentially done on machine tools, which may be Lathe, Milling,
Drilling, Shaping, Planing, Broaching and Grinding machines.
The functions of machine tools are:

holding the workpiece

holding the tool

moving the tool or the work piece or both relative to each other,

supply energy required to cause metal cutting.

Every machine tool has a primary cutting tool for metal removal. And the different cutting
parameters are
Cutting Speed: Cutting speed is the distance traveled by the work surface in unit time
with reference to the cutting edge of the tool or the speed of tool with respect to the
workpiece. The cutting speed, v is simply referred to as speed and usually expressed in
m/min.
Feed: The feed is the distance advanced by the tool into or along the workpiece each time
the tool point passes a certain position in its travel over the surface. Feed f is usually
expressed in mm/rev. Sometimes it is also expressed in mm/min and is called feed rate.
Depth of cut: It is the distance through which the cutting tool is plunged into the
workpiece surface. Thus it is the distance measured perpendicularly between the
machined surface and the machined (uncut) surface or the previously machined surface
of the workpiece. The depth of cut d is expressed in mm.

During machining different cutting parameters will affect the tool life, surface finish of
workpiece because depending on the parameters forces will be induced and heat will be
generated etc. So different Machining tests are performed to get the effect of different
cutting parameters. The parameters which predominantly affect the tool life are cutting
speed, feed and depth of cut by the equation given by Taylor,

The selection of cutting speed and feed is based on the following parameters:

Workpiece material
Tool Material
Tool geometry and dimensions
Size of chip cross-section
Types of finish desired
Rigidity of the machine
Types of coolant used

Specimen and equipment:

Sample workpiece
Tool with HCS tip
Shaper machine
Tool dynamometer
Amplifier
Computer

Working Principle:
To measure the forces, the dynamometer will be placed at the location where the forces
have to be measured (in case of shaper under the workpiece). The working principle of
dynamometer is based on the principle of piezoelectricity. When the force is applied on
the quartzs crystal (piezoelectric material), it undergoes the strain and it will generate
emf across it in millivolts. While machining, the force exerted by the tool on the workpiece
in three different directions will strain the piezoelectric material in different amounts in
the three directions, which causes emf across them. This emf is sensed by the sensor and
sent to the amplifier, where it is amplified and sent to computer, where the forces will be
calculated and displayed.

About Machine:
ShaperA shaper is a type of machine tool that uses linear relative motion between the
workpiece and a single-point cutting tool to machine a linear toolpath. Its cut is
analogous to that of a lathe, except that it is (archetypally) linear instead of helical.
The shaper gives us a wide variety of feeds, cutting speeds and depth of cut. It has
high degree of accuracy and rigidity, which are required for the metal machining
processes.
Different parts of a shaper machine are:
Tool feed handle-used to give the feed.
Tool post-used to hold the tool during operation.
Vice-used to hold the workpiece during operation.
Table-holds the vice.
Adjustable sliding support-for positioning of workpiece. (can move in x and z
direction)
Graduated collar-to adjust the stroke length.
Clutch handle-to engage and disengage of ram with driving unit.
Hand wheel-for manually operating the ram motion.

Machine tool dynamometerA machine-tool dynamometer is a multi-component dynamometer that is used to

measure forces during the use of the machine tool. Empirical calculations of these forces
can be cross-checked and verified experimentally using these machine tool
dynamometers.
With advances in technology, machine-tool dynamometers are increasingly used for the
accurate measurement of forces and for optimizing the machining process. These multicomponent forces are measured as an individual component force in each co-ordinate,
depending on the coordinate system used. The forces during machining are dependent
on depth of cut, feed rate, cutting speed, tool material and geometry, material of the
work piece and other factors such as use of lubrication/cooling during machining.
Tool Dynamometer is a cutting force measuring instrument used to measure the cutting
forces coming on the tool tip of a shaper Machine. The sensor is designed in such a way
that it can be rigidly mounted on the vice and the workpiece can be fixed to the sensor
directly. This feature will help to measure the forces accurately without loss of the force.
Forces in X - Y - Z directions will be shown individually & simultaneously.

Procedure:
Fix dynamometer and workpiece (on top of dynamometer) on the shaper machine
using vice.
Switch on the machine.
Measure the work co-ordinates zero reference by touching the tool tip on top
surface of workpiece by using tool feed handle and hand wheel.
Ensure that tool tip is just touching the top surface of workpiece and moving freely
during the forward stroke using hand wheel.
Make all the necessary connections for the dynamometer required for
measurement.

Setting the parameters in dynamometer software:

Open the dyno ware software in the computer.
Select acquisition and select edit option to set the parameters of dynamometer.
After giving all the parameters and specifying the directory, where the results will
be stored, press apply and then ok.
Select view and select documentation to set the RPM of spindle. Ensure that the
RPM value in the software and the RPM value used in machine are same.
Select acquisition and then hardware.
Select send parameter, measure option, then apply and press ok.
Select acquisition and then start.
Select apply and press ok.
Start shaper machine by slowly releasing the clutch handle and parallely give the
feed by using tool feed handle.
Simultaneously press go option in the computer to record the tool cutting force.

Finally, Time vs Force graph will be plotted by software.

Testing:

In the current experiment

Experiment has been carried out on Aluminum workpiece.
At various depth of cut while the cutting velocity was held as constant, the forces
were measured using the dynamometer.

Result:
The results show that increasing feed rate increased cutting forces.

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Conclusion:
As a conclusion, the objective of this experiment is successfully achieved.

Points to Remember:

1
2
3
4

Dos
Check all the connections properly.
Fix the dynamometer carefully.
Slowly give the depth of cut.
Ensure no obstacle exists along the
tool travel length.

Donts
Dont go near machine.
Dont give more depth of cut, it may
damage the dynamometer.