GRINDING FORCE DYNAMOMETER

A
PROPJECT
SUBMITTED IN PARTIAL FULFILLMENT FOR THE
AWARD OF THE DEGREE

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

UNDER THE GUIDENCE OF

MR.SAIKH HIKM

GLOBAL INSTITUTE OF MANAGEMENT AND TECHNOLOGY (GIMT)

Approved by AICTE &Affilated to MAULANA ABUL KALAM AZAD UNIVERSITY OF

TECHNOLOGY (MAKAUT) WB

SUBMITTED BY
SL.NO NAME ROLL

BIKASH BHASKAR
ANIL KUMAR SAW
SHAYAN MALLICK
GOVIND KUMAR RAM
GAUTAM KUMAR MANDAL
SHERFUL ALAM BAIDYA
SUKANTA GUIN
RAJA DEBNATH
SUMIT KUMAR BOSS
DECLARATION
We hereby declare that this submission is our own work to the best of our knowledge
and belief, it contains no material previously or written by any other person nor
material which to substantial extent has been accepted for the award of any degree
Or diploma of the university or other institute of higher learning, except where due
acknowledgement and references has been made in the text.

SL Name Roll no Sign

NO.
BIKASH BHASKAR
ANIL KUMAR SAW
SHAYAN MALLICK
GOVIND KUMAR RAM
GAUTAM KUMAR MANDAL
SHERFUL ALAM BAIDYA
SUKANTA GUIN
RAJA DEBNATH
SUMIT KUMAR BOSS

CERTIFICATE
This is certify that project report entitled “GRINDING FORCE
DYNAMOMETER” Which is being submitted by the name of BIKASH
BHASKAR, ANIL KUMAR SAW, SHAYAN MALLICK, GOVIND KUMAR RAM,
GAUTAM MANDAL SHERFUL ALAM BAIDYA, SUKANTA GUIN, SUMIT
KUMAR BOSS, RAJA DEBNATH, in the partial fulfillment for the requirement
for the award of the degree of bachelor of technology in department of ME Of
GIMT ,KRISHNAGAR (MAKAUT).They have worked under the guidance of
(Asst. prof. SAIKH HIKMAT OF ME) and have fulfilled the requirement for
the submission of project.

The matter presented in this dissertation has not been submitted by me

anywhere for the award of any other degree this or any other institution .

Your name…..

This is certify that the above statement made by the candidate is correct

And true to the best of our knowledge

Dr……………….. prof…………………

(SUPERVISOR) (CO SUPERVISO)

The B.Tech viva voice examination of has been held on

…………….. ……………… ……………….. …………

Supervisor co-supervisor HOD External

ABSTRACT
Grinding dynamometers are used to measure radial and feed forces
between grinding wheel and the work piece in a plunge surface
grinding operation. The essential requirements of dynamometer are
its mechanical rigidity and sensitivity. In this paper, an octagonal
extended ring type dynamometer has been designed, fabricated and
calibrated, which describes the set up, fabrication, mounting of strain
gauges and calibration. Stainless steel is chosen as constructional
material, and strain gauges are cemented on the surface of the
dynamometer. The two terminals of the strain gauges are fitted on an
arm of Whetstone bridge circuit. A linear operational amplifier has
been used as a force measurement display unit to measure directly
the force components. The experimental results are analyzed and
presented. The main results are: feed and radial forces during
electrochemical grinding are very less compared to conventional
grinding for similar conditions, with the increase of feed rate they
increase and the feed force is about half of the radial force, process
efficiency increases with the increase in current density and
decreases with the increase in feed force.
 TABLE OF CONTENTS

CHAPTER TITLE PAGE NO

DECLARATION

CERTIFICATE

ACKNOWLEDGEMENT

1 INTRODUCTION

2 FABRIOCATION

LIST OF FIGURE

3 STRAIN GAUGE

LIST OF FIGURE

4 PRINCIPAL & WORKING OF STRAIN GAUGE

LIST OF FIGURE

5 GRINDING FORCE DYNAMETER

COCLUSION

REFRENCE
 INTRODUCTION

There are many methods for measuring two components of grinding

force and elongated octagonal rings are used mainly for two
dimensional dynamometer in grinding operations. An industrial
model for electrochemical grinding machine with hydraulic feed
control has been developed at Indian Institute of Technology (IIT),
Kharagpur , India. A grinding dynamometer has been incorporated to
measure force components produced during machining operation of
tungsten carbide and stainless steel. In the design and application of
metal cutting tools, it is very much essential to know the forces which
act upon the tool as well as on the machine tools, and the fixture and
power required under a given set of cutting condition for the purpose,
it is essential to study the effect of different variables of cutting on
cutting forces. [ Ponkshe, 1966] .Among the cutting variables, feed
rate and current density play an important role that influence the
magnitude of cutting forces in ECG process. Many research workers
[Ito et al., 1980 & Bhowmick and Mishra, 1998] have carried out
some experiment toterminals of the strain gauges are fitted to an arm
of a Whetstone bridge circuit.

Many researchers [Ito et al., 1980 and Bhowmick and Mishra, 1998]
suggested that the dynamometer should possess the following
characteristics: i) It should be simple in design and easy to handle
and vice versa. ii) It would be rigid enough so as not to give rise to
vibrations at least within the operating range. iii) It should be
sufficiently elastic so as to give an appreciable deformation on all
bodies. Its measuring element should be sensitive and should be free
from cross-effects so far as possible. iv) It should be stable and
unaffected by humidity and temperature variations. It should also
give consistent readings with passage of time. v) The calibration
curves should be fairly linear and facilities interpolation of the
intermediate ranges. vi) The frequency response of the dynamometer
should be high enough so that the results are accurately noted
unaffected by 'dynamic instability' of the measuring system. The
common feature in all types of dynamometers is the measuring
springs whose deflections are proportional to cutting forces. The
major difference in the design of various dynamometers lies in the
technique employed to measure spring deflectionTwo components of
force namely radial and feed are measured with the help of a grinding
dynamometer. Normally, the dynamometer forms a link between the
work and machine bed in ECG process. An octagonal extended ring
type dynamometer has been designed, constructed and calibrated.
Completely circular rings are not considered because they have a
tendency of rolling under the action of cutting forces. Octagonal rings
are used to avoid the rolling tendencies. In an elongated octagonal
ring, the rigidity and the output per unit displacement decreases [Ito
ET al., 1980] The essential requirement of the dynamometer used for
ECG in its sensitivity to measure the grinding forces with sufficient
accuracy. The design is based on conventional size to handle,
accuracy of measurement provision for modification, provision for
change of parameter, mechanical loading and sensitivity. Keeping the
essential requirements of a good dynamometer in view, stainless steel
is chosen as constructional material. Besides the above, the specialty
of the stainless steel is its non-corrosiveness which is very much
essential for ECG process.
 FABRICATION

Fabrication All the fabrication works are performed in house. A

rectangular stainless steel block is roughly made for maximum stock
removal and then machined to get the desired size as shown in Fig.1.
In making the octagonal rings, two holes are drilled by radial drilling
machine followed by boring operation. A stainless steel block is cut
into an octagonal shape with the help of a vertical milling machine.
The slit between the two horizontal members is made using a slitting
saw in column and knee type horizontal milling machine. Finally, all
the surfaces are ground and polished. Two blind holes are made on
the dynamometer to fit with the vice by nutbolt system.

Fig. 1 Designed Dimension of the Dynamometer

 STRAIN GAUGE

A Strain gauge (sometimes refered to as a Strain gage) is a sensor

whose resistance varies with applied force; It converts force,
pressure, tension, weight, etc., into a change in electrical resistance
which can then be measured. When external forces are applied to a
stationary object, stress and strain are the result. Stress is defined as
the object's internal resisting forces, and strain is defined as the
displacement and deformation that occur.

The strain gauge is one of the most important sensor of the electrical
measurement technique applied to the measurement of mechanical
quantities.

Fig.Strain gauge
As their name indicates, they are used for the measurement of
strain. As a technical term "strain" consists of tensile and
compressive strain, distinguished by a positive or negative sign.
Thus, strain gauges can be used to pick up expansion as well as
contraction.

Fig. Actual view of strain gauge

The strain of a body is always caused by an external influence or an

internal effect. Strain might be causforces, pressures, moments,
heat, structural changes of the material and the like. If certain
conditions are fulfilled, the amount or the value of the influencing
quantity can be derived from the measured strain value. In
experimental stress analysis this feature is widely used.
Experimental stress analysis uses the strain values measured on the
surface of a specimen, or structural part, to state the stress in the
material and also to predict its safety and endurance. Special
transducers can be designed for the measurement of forces or other
derived quantities, e.g., moments, pressures, accelerations,
displacements, vibrations and others. The transducer generally
contains a pressure sensitive diaphragm with strain gauges bonded
to it.

PRINCIPLE AND WORKING OF STRAIN GAUGE

PRINCIPLE : It works on the principle of wheat stone bridge.

WHEAT STONE BRIDGE

The device uses for the measurement of minimum resistance with the help of
comparison method is know as the Wheatstone bridge. The value of unknown
resistance is determined by comparing it with the known resistance. The
Wheatstone bridge works on the principle of null deflection, i.e. the ratio of
their resistances are equal, and no current flows through the galvanometer.
The bridge is very reliable and gives an accurate result.

Strain Gauge based weight sensor

 Working 0f strain gauge
In order to measure strain with a bonded resistance strain
gauge, it must be connected to an electric circuit that is
capable of measuring the minute changes in resistance
corresponding to strain. Strain gauge transducers usually
employ four strain gauge elements electrically connected to
form a Wheatstone bridge circuit.

Fig. 10.12 Measuring Strain with Strain Gages

A Wheatstone bridge is a divided bridge circuit used for the

measurement of static or dynamic electrical resistance. The output
voltage of the Wheatstone bridge circuit is expressed in millivolts
output per volt input. The Wheatstone circuit is also well suited for
temperature compensation.

The equation of the Wheatstone bridge, if R1, R2, R3, and R4 are
equal, and a voltage, VIN, is applied between points A and C, then the
output between points B and D will show no potential difference.
However, if R4 is changed to some value which does not equal R1,
R2, and R3, the bridge will become unbalanced and a voltage will
exist at the output terminals. In a so-called G-bridge
configuration, the variable strain sensor has resistance Rg, while
the other arms are fixed value resistors.

The sensor, however, can occupy one, two, or four arms of the
Wheatstone bridge, depending on the application. The total
strain, or output voltage of the circuit (VOUT) is equivalent to the
difference between the voltage drop.

:
 GRINDING FORCE DYNAMOMETER

The construction and application of a strain gauge type (extended

O-ring) grinding surface dynamometer and another piezoelectric
type are typically shown in figure.
conclusion
In this study, a force measurement setup that can measure the
tangential and normal grinding forces by using strain gauge
has been developed. The detailed investigation was
conducted in ANSYS to analyze and identify the region of
strain in the stationery tailstock in the cylindrical grinding
due to grinding forces. It is observed from the ANSYS
results that the elastic deformation is more in the area of
conical portion of the dead center and it increase with an
increase in the load. From the result the position of placing
the strain gauge has been identified which will be subjected
to considerable stress.
The force measurement circuits, the procedure for recording the
grinding force signal, calibration of the experimental setup have
been described. The tangential grinding force was measured and
also derived from the measured grinding power, and both values
have fairly agreed.
It is observed from the grinding force signal plot, the
tangential and normal grinding force signals have same trend
and the maximum amplitude of force signal has been found
at the time of full contact between the wheel and the work
piece.
 REFRENCE

https://www.nptel.in
www.wikipedia.com
https://www.omega.co.uk
http://www.allaboutcircuits.com
www.omega.com
www.automationforum.com