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Cutting Force

Measurement

Precise Measuring
Systems for
Metal-Cutting
Kistler
Your Partner for Efciency and Quality
Sensors and systems for measuring forces Year after year the company invests 10 %
and torques, analyzing force-displacement of its sales in R&D to facilitate technically
and force-time characteristics, and docu- innovative yet cost-effective state of the
menting quality data during assembly and art solutions.
product testing are just a few elements of
the solutions for the sector provided by With a combined workforce of around
Kistler Instruments AG. From our head- 1 000, the Kistler Group is the world mar-
quarters in Switzerland, we supply as- ket leader in dynamic measurement tech-
sembly and testing technology as well as nology. Twenty-three group companies
specific sensors and monitoring systems worldwide and more than 30 distributors
for combustion engines, automotive engi- ensure close contact with the customer,
neering, plastics processing and biome- individual application engineering support
chanical engineering. and short lead times.

Kistler's core competency lies in the de-


velopment, production and implementa-
tion of sensors for pressure, force, torque
and acceleration measurement. Kistler
electronic systems and expertise used for
conditioning measurement signals allow
analysis, control and optimization of
physical processes as well as enhancement
of product quality for the manufacturing
industry.

PiezoStar Kistler has been growing its


own highly sensitive and thermally stable
crystals for more than ten years

www.kistler.com
Contents

Cutting Force Measurement 4

Process Optimization 5

Measuring Instruments 6

Measuring Chain 7

Multi-Component Force and Moment Measuring 8

Kistler Measurement Technology 10


Basics of Piezoelectric Measurement Technology 11
Basics of Calibration 13
Accuracy Evaluation 18

Cutting Force Measurement


during Turning 20
during Milling 21
during Drilling 22
during Grinding 23
for Special Applications 24

Torque Measurement during Machining 25

Dynamometer Selection Table 26

Product Information

Measuring: Stationary Dynamometer 27

Measuring: Rotating Dynamometer 32

Amplifying: Charge Amplifier 34

Analyzing: Software 36

Connecting: Connecting Cable, multi-core 37

Accessories: Electronics 41

www.kistler.com 3
Cutting Force Measurement

Signicant cutting force and spindle or Kistler has been involved in challenging New, forward-looking products for econo-
drilling torque data is very important in multi-component force measuring tech- mically optimizing machining processes or
ensuring the process optimization invol- nology for use in cutting force measure- developing new tools has given Kistler its
ment for more than four decades. leading international position.
ved in metal cutting machining. Analyz-
Ongoing development of sensor techno-
ing cutting forces prior to the start of logy now allows recording of the cutting
production increases process capability force during grinding, drilling, turning, What is Achieved by Measuring
and boosts productivity. The detection of milling and tapping. This is achieved with the Cutting Forces?
overloads, tool collisions and tool break- stationary or rotating "dynamometers".
Analysis of cutting technology
age can also be monitored with the aid of The acquired signals are evaluated with
Optimization of cutting parameters
the aid of electronics and software solu-
Kistler sensor systems. Improvement of cutting processes
tions.

Machining remains the most important


type of forming. However, this method of
production has changed significantly over
recent decades, with cutting process re-
quirements becoming ever more stringent.
Products of impressive quality are expect-
ed to be achieved with individual machin-
ing operations while remaining cost-effec-
tive and sustainable. Detailed knowledge
of the cutting processes is indispensable
in actually meeting these requirements.
The acting forces and torques, which are
essential prerequisites for drawing conclu-
sions about the technology and cutting
parameters, are important indicators here.
These forces can only be measured and
hence analyzed with sophisticated sensor
solutions.

Cutting

Grinding Drilling Turning Milling Tapping

4 www.kistler.com
Process Optimization

Because general cutting value documents Profitability and superlative quality


Factors Determining the
cannot be transferred from factory to combined in Kistler dynamometers
Magnitude and Direction of
factory or from machine to machine, each Process optimization, in which Kistler
Cutting Forces
user must have his own cutting data avail- dynamometers play an important role,
able. allows a considerable increase in the effi- Cutting speed
ciency of cutting processes in manufactur- Cutting depth
Dynamometers, which measure all of the ing plants. The data provided by Kistler Feed rate
components of the cutting force, are dynamometers can be used to reduce Stock material
invaluable in research, tool manufacture production costs. Critical factors during Cutting material
and production technology. They are used production and production engineering Coating cutting edges
in analyzing, comparing and selecting can be eliminated in advance. Cutting geometry
materials, tools and machines. Additional Tool manufacturers have the confidence Cutting fluid
areas of application result from defining that they are offering optimized products.
optimum cutting conditions, analyzing the
breakage behavior of tools and the chip
formation process and their influence on
cutting forces.

www.kistler.com 5
Measuring Instruments

Fx
Technology Mz
Fx
Piezoelectric force measuring systems are Fz
considerably different from other methods
of measurement. The forces acting on the Fz
quartz crystal element are converted to a Fy

proportional electric charge. The measur-


Fx Fy
ing path of a piezoelectric force measuring
element amounts to just a few thou- Fx
Fy
sandths of a millimeter. The measuring
Fz
range of such an element is very large. Mz Fy
Fz
Dynamometers from Kistler are very
compact, rigid systems and therefore
have a high natural frequency. This allows Fx
Fz
precise measurement of highly dynamic Fy
events. Dynamometers are designed to
ensure that, at less than 1 %, the problem Fx Fx
of crosstalk becomes very minor. Their
rust-resistant design is protected against Fy Mz Fy
ingress of cutting fluid to achieve an Fz Fz
IP67 rating. The quality of these systems
ensures an almost unlimited service life.
Piezoelectric force sensors do not require
zero adjustment for this purpose they
are ready to operate at the push of a but-
ton.
Construction of a 3-component dynamometer Construction of a 4-component dynamometer
(Fx, Fy, Fz) (Fx, Fy, Fz, Mz)

Advantages of Kistler 3-Component Dynamometer 4-Component Dynamometer


Dynamometers
Two shear quartz for Fx and Fy and Multiple quartz plates can be connected
+ High rigidity and consequently one pressure quartz for Fz incorpora- electrically and mechanically in parallel.
high natural frequency ted in a single case constitute a 3-com- When shear-sensitive plates are arranged
ponent sensor. in a circle so that their shear-sensitive axes
+ Wide measuring range
are tangential, this results in an arrange-
+ Extremely low crosstalk (below 1 %) Four of these 3-component sensors are ment which responds to a moment Mz.
installed between a base plate and a top
+ Compact design
plate under high preload and connected in When these are combined with two shear
+ Unlimited life parallel. They thus constitute a 3-compo- quartz for Fx and Fy and one pressure
nent dynamometer. The outputs of the quartz for Fz this results in a 4-compo-
+ Cutting fluid proof according
four built-in force sensors are intercon- nent sensor assembled in a single case.
to degree of protection IP67
nected in the dynamometer in such a
+ Simple operation (ready to measure manner that multi-component force and When this sensor is fitted between a base
at the "push of a button") moment measurements are also possible. plate and a top plate under high preload,
The four sensors are ground-isolated a 4-component sensor is created for Fx, Fy,
thereby largely eliminating ground loop Fz and Mz.
problems.

6 www.kistler.com
Measuring Chain

The Measuring System Multichannel Charge Amplifier Data Acquisition


The heart of a system for measuring Multi-component dynamometers require Kistler provides extremely useful software
cutting forces is the actual instrument, a a corresponding number of measuring for data acquisition and analysis. Kistler's
dynamometer. It is used to measure the channels. In this respect, Kistlers multi- DynoWare allows setting of all of the
acting forces and (depending on type) channel charge amplifiers leave nothing important charge amplifier parameters
torques. Dynamometers based on the to be desired. These instruments are avail- to data acquisition. The acquired data is
piezoelectric principle output a charge able with optional numbers of channels. represented graphically and, in conjunc-
proportional to the measurand. These Thanks to the intuitive menu system the tion with the various signal processing
charges are then passed on via a high- parameters can be conveniently config- functions, makes it easier to analyze the
insulation cable to the charge amplifier for ured on the charge amplifier or activated cutting force. DynoWare also provides a
conversion into proportional voltages. directly with the computer via the built-in simple means of documenting and export-
interface. ing the data. This software package is an
The reliability of the system is also important instrument allowing any user to
extremely important when measuring acquire and subsequently analyze cutting
cutting forces. In order to be able to guar- force data.
antee this, Kistler places great emphasis
on coordinating components properly at
the planning stage. In the measuring
system for cutting forces, particular atten-
tion is given to the stability and sealing of
individual components against cutting
fluid and other contamination. All dyna-
mometers and cables are ground-isolated
and guarantee interference-free opera-
tion.

Uniform Cable Concept


A reliable connection between the dyna-
mometer and the in-line charge amplifier
is of paramount importance to measure-
ment stability. The ground-isolated cables
for measuring cutting force are protected
with a sealed metal sheath that makes
them suitable for use in a machining shop.
Both ends of the cables are provided with
robust connectors that ensure the con-
nection to the stationary dynamometer
achieves IP67 degree of protection. A uni-
form cable concept provides clarity and
simplifies application.

www.kistler.com 7
Multi-Component Force and Moment Measurement

Stationary dynamometer Types 9129AA,


9253B..., 9255B, 9256C..., 9257B, 9265B
and 9366CC... can be used both as
3-component dynamometers and option-
ally for 6-component force and moment
measurement.

For cutting force measurement, in addi-


tion to the three orthogonal force compo-
nents Fx, Fy and Fz, only the moment Mz is Fx1+2
relevant for determining the drilling mo-
a Fx3+4
ment.
Fy1+4

In addition to cutting force measurement, Fy2+3


there are innumerable other measuring Fz1
tasks, in which both the three components Fz2
of the resulting force and the three com- Fz3
ponents of the resulting moment vector a Fz4
are of interest.

b b

Calculation the forces


Calculation of the three forces Fx, Fy, Fz and three moments Mx, My, Mz
Three forces Fx, Fy and Fz and the mo-
ments Mx, My and Mz are calculated in a
Fx = Fx1+2 + Fx3+4
computer or with the 6 component sum-
ming amplifier in the charge amplifier. To
Fy = Fy1+4 + Fy2+3
calculate the moments, the distance of the
sensors must be included. The dynamom-
Fz = Fz1 + Fz2 + Fz3 + Fz4
eter must be appropriately calibrated for
accurate moment measurement.
Mx = b ( Fz1 + Fz2 Fz3 Fz4 )

My = a ( Fz1 + Fz2 + Fz3 Fz4 )

Mz = b ( Fx1+2 + Fx3+4 ) + a ( Fy1+4 Fy2+3 )

8 www.kistler.com
3-core connecting cable 8-core connecting cable
In General, a 6-Component
Measuring System Provides
3 charge amp. channels 8 charge amp. channels
The three components of the
resultants of all applied forces,
Fx Fx1+2 their direction but not their
Fx3+4 location in space
Fy Fy1+4
The three components of the
Fy2+3 resulting moment vector related
Fz Fz1 to the coordinate origin
Fz2
Fz3
Fz4

3-component force measurement 6-component force measurement


In 3-component force measurement, the In 6-component force and moment
eight output signals from the dynamome- measurement, the eight output signals are
ter, as shown in the illustration, are fed directly to the eight charge amplifiers
summed in the three-core connecting by the eight-core connecting cable.
cable. Three charge amplifiers are needed
to convert the charge signal to a propor-
tional output voltage.

www.kistler.com 9
Kistler Measurement Technology

Kistler supplies piezoelectric, piezoresis- In 1950, Walter P. Kistler received a pat- Quartz at a Glance
tive, capacitive and strain gage sensors. ent for the very first charge amplifier for
Piezoelectric designs are particularly piezoelectric signals, paving the way for Quartz has excellent properties
exploitation of an effect that had been for use as a measuring element:
suitable for measurement imposing
known for decades. The development of High permissible surface pressure
extreme requirements in terms of geom-
highly insulating materials such as Teflon of at least 150 N/mm2
etry, temperature range and dynamics. and Kapton significantly improved the
Kistler therefore relies on the piezo- performance of these measuring systems Withstands temperatures
electric principle for measuring cutting and propelled the use of piezoelectric up to 300 C
forces. sensors into virtually all areas of modern Very high rigidity
technology and industry.
High linearity
Piezoelectric (derived from the Greek Most Kistler sensors rely on a quartz force Negligible hysteresis
piezein, which means to squeeze or press) link, which basically consists of thin quartz
materials generate an electric charge plates, disks/washers or rods. The sensor Virtually constant sensitivity over
when subjected to mechanical load. Pierre is connected to an electronic device for a wide temperature range
and Jacques Curie discovered the piezo- converting the charge signal into a volt- Wide frequency range
electric effect in 1880. As electric charges age signal proportional to the mechanical
do not readily lend themselves to ex- force. The conversion is made either by Virtually unlimited number
perimental research, piezoelectricity only means of a separate charge amplifier or an of load cycles
gained practical significance in the middle impedance converter with coupler, which
of the 20th century. With the help of so- is usually integrated into the sensor.
called electrometer amplifiers, the charge
produced by piezoelectric material could The finite insulation resistance does not combination with suitable signal condi-
then be converted into a proportional permit truly static measurement with tioners, piezoelectric sensors offer excel-
electric voltage for the very first time. piezoelectric sensors. Nonetheless, used in lent quasistatic measuring properties.

10 www.kistler.com
Basics of Piezoelectric Measurement Technology

Longitudinal effect
A charge is developed on the surfaces to Unloaded crystal Crystal under load
which the force is applied, where it can be
measured. In the case of the longitudinal
piezoelectric effect, the magnitude of the Principle of the
electric charge Q depends only on the longitudinal
applied force Fx and not on the dimen- piezoelectric effect
sions of the crystal disks. The only way to
increase this charge is to connect several
disks mechanically in series and electrically
in parallel. The magnitude of the output
charge then becomes:

Qx = d11 Fx n
The piezoelectric coefficient d11 is de-
Crystal
pendent on direction and indicates the
Potential for disk
crystal's degree of force sensitivity in
the direction of the corresponding axis. increasing the
The position of the crystal cut therefore charge output
determines the properties and the area of
application of the quartz force link. Piezo-
electric elements cut to produce the longi-
tudinal effect are sensitive to compression
forces and therefore suitable for simple
and sturdy sensors for measuring forces.

Shear effect
Similarly to the longitudinal effect, the
piezoelectric sensitivity involved in the Unloaded crystal Crystal under load
shear effect is independent of the size
and shape of the piezoelectric element.
The charge is also developed on the piezo
Principle of the
elements loaded surfaces. In the case
shear effect
of a load in the x-direction applied to n
elements connected mechanically in series
and electrically in parallel, the charge is:

Qx = 2 d11 Fx n
Shear-sensitive piezo elements are used
for sensors measuring shear forces,
torque and strain. They are suitable for
manufacturing sensors whose excellent Direction of
performance is unaffected by temperature applied force
changes, as the changes in the stresses in
the sensor structure caused by changes in
the temperature act in a direction perpen- z
dicular to the sensitive shear axis.

d11: piezoelectric coefficient Fx: force in x-direction


( 2,3 pC/N for quartz crystals) n: number of crystal disks

www.kistler.com 11
Kistler Measurement Technology

Charge Ampliers
Charge amplier
Charge ampliers convert the charge
produced by a piezoelectric sensor into a
proportional voltage, which is used as an
input variable for monitoring and control
processes. A charge amplier basically
consists of an inverting voltage amplier
with high open-loop gain and capaci-
tive negative feedback. It has a metal Sensor Cable
oxide semiconductor eld effect transis-
tor (MOSFET) or a junction eld effect
transistor (JFET) at its input to create the
necessary high insulation resistance and
Q
ensure a minimum of leakage current.
Neglecting Rt and Ri, the resulting output
voltage becomes:
Uo = Output voltage Rt = Time constant resistance
A = Gain (or insulation resistance of range capacitor)
-Q 1 Ct = Sensor capacitance Ri = Input insulation resistance
Uo =
Cr
1
1 + AC (Ct + Cr + Cc )
Cc = Cable capacitance
Cr = Range or negative
(cable and sensor)
Q = electric charge yielded by the
r feedback capacitor piezoelectric element

If the open-loop gain is sufciently high,


the quotient 1/ACr will approach zero.
The cable and sensor capacitance can Block diagram of a measuring chain

therefore be neglected, leaving the output


voltage dependent only on the input Time constant and drift ditional time constant resistor is connected
charge and the range capacitance. Two of the more important considerations in parallel, the charge amplier will drift
in the practical use of charge ampliers relatively slowly towards the negative
-Q are time constant and drift. The time or positive limit (MOSFET: <0,03 pC/s,
Uo =
Cr constant is defined as the discharge time JFET: <0,3 pC/s). This determines the
of a capacitor by which 1/e (37 %) of the potential duration of quasistatic measure-
The amplier acts as a charge integra- initial value has been reached. The time ment and is independent of the selected
tor that constantly compensates for the constant of a charge amplifier is deter- measuring range.
sensor's electrical charge with a charge of mined by the product of the capacitance
equal magnitude and opposite polar- of the range capacitor Cr and the time Frequency and time domain
ity on the range capacitor. The voltage constant resistance Rt: The time constant affects the time domain
across the range capacitor is proportional as well as the frequency range. It deter-
to the charge generated by the sensor = RtCr mines the lower cut-off frequency fu =
and therefore proportional to the acting at an amplitude attenuation for
measurand. In effect, the charge amplier Drift is dened as an undesirable change sinusoidal signals of 3 dB (30 %). The
converts an electric charge input Q into in the output signal over a long period of longer the time constant, the better this
an easily usable proportional output volt- time that is not a function of the measu- frequency and the longer the usable mea-
age Uo. As most Kistler charge ampliers rand. Even the best MOSFETs and JFETs suring time. For quasistatic measurement
allow adjustment of sensor sensitivity and have leakage currents (MOSFET: Il <10 fA, during assembly and testing, the longest
measuring range, the measured value is JFET: Il < 100 fA), which are the main cau- possible time constant is always selected.
displayed directly in mechanical units of se of drift. If the input insulation resistance
the measurand and the output signal is Ri is too low, it can cause additional drift.
an integer multiple of the measurand. However, as long as the input insulation
resistance in the negative feedback circuit
is sufciently high (>1013 ) and no ad-

12 www.kistler.com
Basics of Calibration

Basic Calibration Terms I Test FSO


Calibration
Calibration is the use of a dened method
under specied conditions to determine I Ref
the relationship between a known input
variable and a measured output variable.
The calibration standard is the reference t
value. For example, the calibration of
-L max
scales involves placing a dened and cal- +L max
ibrated test weight (calibration standard)
H max
on the scales to reveal deviations in the
weight reading.

Calibration certicate
The calibration certicate documents all I Test
L: Linearity
values measured during calibration and H: Hysteresis
the calibration conditions.
I Ref Measuring range I Ref
Calibration curve
Hysteresis: maximum difference between rising and falling load characteristic
This curve shows the output variable of a
sensor as a function of the input variable.
Linearity Sensitivity
Calibration standard In practical application there is not an Value of the change in output signal di-
The calibration standard, which is trace- exactly linear (or constant) relationship vided by the corresponding change in the
able to national or international "stan- between the measurand and the output input variable: Q/IRef for piezoelectric
dards", is the reference value used for variable of the sensor. The linearity Lmax sensors.
calibrating sensors or measuring instru- of a sensor corresponds to the maximum
ments. deviation of the ideal from the actual out-
put signal curve in relation to the measur-
Characteristic value and within a certain measuring range. It is
Output signal of the strain gage sensor expressed as a percentage of the limit of
at rated load, reduced by the zero signal the full measuring range (% FSO).
after mounting.

FSO I Test FSO


Full Scale Output or full range signal.
The difference between the output signal +L max
at zero and at the end of the measuring IRef
range.

Hysteresis
t
Maximum difference, Hmax, between
rising load characteristic and falling load IRef
characteristic.
I Test
-L max

L: Linearity
The relationship between the true value of the
measurand and the output variable of the sensor is
not exactly linear
Measuring range I Ref

www.kistler.com 13
Kistler Measurement Technology

Sensors and measuring instruments must


be calibrated at regular intervals, as their Product (sensor) being calibrated
characteristics and hence the measure-
ment uncertainties can change over time
as a result of frequent use, aging and
Known
environmental factors. Instruments used Output
input
for calibration are traceable to national signal
variable
standards and subject to a uniform
international quality control. Calibration
certicates document calibration values
and conditions.
Force Sensitivity Charge
100 N 4 pC/N Q 400 pC
Safe and reliable measurement
Quality assurance systems and product Torque
100 Nm
liability laws call for systematic monitoring
of all test equipment needed for measur- Piezo

ing quality characteristics. This is the only


way of ensuring measurement and test This involves determining the deviation Calibration at a Glance
results provide a reliable and dependable of the measured value from an agreed
benchmark for quality control. reference value, which is also referred to Calibration helps ensure
as the calibration standard. The result of Precise and reliable measurement
All sensors and almost all electronic mea- a calibration can either be used to assign
suring devices are subject to certain mea- the actual values of the measurand to the Internationally comparable
surement uncertainties. As the deviations readings or for establishing correction fac- measurements
involved can change over time, the test tors for them. The required information is Similar products are metrologicaly
equipment must be calibrated at regular documented on the calibration certicate. compatible
intervals.

Basic principle: Calibration is the use


of a dened method under specied
conditions to determine the relationship I Test FSO
between a known input variable and a
measured output variable.

I Ref

t
IRef

I Test

Sensitivity: Ratio of the change in the signal ITest and


the change in the reference variable IRef , where I Measuring range I Ref
represents a charge, voltage or other indicated variable

14 www.kistler.com
Basics of Calibration

The relationship between measurand Calibration Methods F


and sensor output variable is determined 100 % FSO
by means of a simple linear regression During calibration, sensors are subjected
analysis. The linearity including hysteresis to known quantities of a physical mea-
indicates that the calibration curve of the surand such as force or torque and the
loading and unloading characteristic has corresponding values of the output vari-
been used to determine the characteristic able recorded. The magnitude of this load
values. is accurately known, as it is measured with
a traceably calibrated "factory standard"
Best straight line at the same time. Depending on the
Determination of a linear function passing method, sensors are calibrated either
through the origin to form the calibration across the entire measuring range or in a
curve, with two parallel straight lines with partial range:
the same gradient and shortest distance at a single point, t = 200 ... 600 s
apart enveloping all of the calibration stepwise at several different points or
values. continuously.

Least squares function Step-by-step calibration involves the ap-


Determination of a linear function to form plication of a dened load with or without
the calibration curve that minimizes the unloading between successive increases or
sum of the squares of the errors (differ- decreases, depending on the calibration
ences between calibration curve and linear method used. The process is halted after
function). each increment until the measurement
stabilizes.

www.kistler.com 15
Kistler Measurement Technology

During continuous calibration, the load Calibration Documents


is continuously increased to the required F
<105 % FSO
value within a dened time and then
reduced to zero within the same time. A To ensure consistent quality standards
"best straight line" passing through the worldwide, the test equipment has to
origin is dened for the resultant charac- meet standard quality assurance criteria.
teristic, which is never exactly linear. The The European series of standards for
gradient of this line corresponds to the quality management systems (EN 29000)
sensitivity of the sensor within the cali- which is identical to the international
brated measuring range. ISO 9000 demands traceability to the
national measuring standards for all mea-
Linearity is determined by the deviation suring instruments used for this purpose.
of the characteristic from the best line.
Hysteresis corresponds to the maximum Hence the result of calibrating a measur-
t = 2 ... 60 s ing device or system is compared with a
difference between rising and falling
characteristic. higher measurement standard. This results
in a "calibration hierarchy" with the na-
Dynamometers that are used for cutting The continuous approach is the most suit- tional measurement standard at the top.
force measurements are factory calibrated. able calibration method for piezoelectric
sensors.

NMI
National
standard

Accredited Calibration
Laboratory SCS 049 and
DKD-37701 in the case of Kistler
Reference standards

Kistler In-House Calibration Laboratory


Working or factory standards

User
Test equipment
Product

16 www.kistler.com
Basics of Calibration

EA
European Cooperation
for Accreditation
APLAC
Asian Pacic
of Laboratories
Laboratory
Accreditation
IAAC Cooperation
Inter American
Accreditation
Cooperation

SADCA
Southern African
Development
Cooperation in PAC
Accreditation Pacic
Accreditation
of Certication

International standards specify the re- The following calibration documents are At a Glance
quired calibration methods and measure- available for most Kistler sensors:
Kistler offers comprehensive calibration
ment uncertainties.
service:
Manufacturer's declaration
Different institutes coordinate interna- CE declaration of conformity Calibration of test equipment
tional cooperation on calibration. They are Factory certicate
also responsible for the accreditation of Test certicate Accredited calibration laboratory
national calibration laboratories. Docu- Factory test certicate (SCS 049 DKD-37701)
mentation guidelines may differ slightly Calibration certicate Extensive functional testing
from one country to another. SCS calibration certicate
Traceability chart Range of different calibration
documents

www.kistler.com 17
Kistler Measurement Technology

Numerous mechanical, electrical and istics. The linearity determined by the Prior to calibration of the sensor, the
climatic parameters affect the calibra- calibration is documented on the calibra- charge amplier must also be calibrated
tion result and hence the accuracy of a tion certicate and affects evaluation of using a precision charge calibrator to
the measuring uncertainties involved in ensure that the output voltage displayed
measuring chain. For maximum calibra-
calibration. The linearity of the reference by the amplier is matched with the
tion accuracy, assembly errors have to sensor is already included in the measure- charge generated by the force sensor.
be avoided and the correct position and ment uncertainty and need not be further The absolute standard method employs
angle of force application achieved. Fac- taken into account. a calibration system with preset physical
tors such as the non-linearity of various input variable. This system also has best
electrical parameters along the measur- Humidity measurement capability.
Relative humidity inuences the behavior
ing chain must be considered. Last but
of electronic components including the Effect of temperature
not least, temperature and humidity also capacitors used in charge ampliers and Mechanical components are subject to
have a decisive effect. charge calibrators. Type approval tests thermal expansion and the resistance
record and document the thermal charac- of electronic components depends on
Simultaneous calibration of three force teristics of electric measuring instruments. temperature. Temperature variation dur-
components or three moments is one This information can be used to determine ing the calibration process therefore has
of the greatest challenges in calibrating the effects of variations in humidity on the a direct effect on the result. The effect of
multicomponent sensors. On Kistler's calibration result. this parameter on the sensitivity of piezo-
3-component calibration system the load- electric sensors is analyzed as part of the
ing is applied sequentially, with the sensor Effective number of bits (ENOB) type approval test. There is also reliable
being calibrated remaining in its mounted Measuring cards, for example, have a data on the thermal behavior of charge
position. measuring range of 10 10 V and a calibrators and charge ampliers. Charge
resolution of 16 bits. The true signal is calibrators have temperature compensa-
Linearity rounded up or down to the nearest bit tion that makes their thermal dependence
The overall characteristic of electrical value, which causes a maximum rounding very slight.
devices is usually non-linear, as linear be- error of half a bit.
havior of all structural components is rare.
This also applies to charge calibrators, Best measurement capability
charge ampliers and bridge ampliers, Comparative calibration involves the use
whose very slight non-linearity affects of a reference sensor with best measure-
the calibration result. Force and torque ment capability, which has a documented
sensors also exhibit non-linear character- measurement uncertainty as a result of
being calibrated against a higher standard.

18 www.kistler.com
Accuracy Evaluation

Range errors in charge ampliers and Instability of charge ampliers over time Crosstalk in multiaxial sensors and
charge calibrators Charge ampliers are subject to instability sensor systems
The tolerance of electric components lim- over time. To minimize the effect of this Complex sensor systems such as dynamo-
its the accuracy of charge ampliers and instability on force sensor calibration, it is meters are generally tted with multicom-
charge calibrators. It manifests itself as a advisable to calibrate the charge ampliers ponent sensors. With such congurations
range error, which depends on the preset of both the reference measuring chain and crosstalk of individual variables is observed
measuring range and the measured value. the measuring chain of the device togeth- in other measurement components. With
The maximum range error is specied for er with all corresponding cables, display a unidirectional force load in the direction
each device. and evaluation devices, in advance with a of one axis minimal signals in the direc-
precision charge calibrator. This approach tion of the other two orthogonal axes or
Drift also identies all potential inuences from minimal moment will be indicated. This
The drift of a charge amplier is a global contacts and electrical connections within phenomenon affects all of the possible
description of the shift of the signal zero the measuring chain. force and moment directions and the val-
level, which is mainly due to a loss of ues involved have to be taken considered
feedback capacitor charge and leakage Stability of charge calibrators in assessing measurement uncertainties.
currents at the amplier input. A leakage Under normal circumstances, charge
current across the insulation resistance calibrators are calibrated at regular inter- Threshold
causes an exponential decay in the feed- vals (generally annually). Within these The threshold is the smallest change in the
back capacitor charge with a time con- intervals the calibration values undergo input variable that leads to a discernable
stant given by the product of insulation slight changes, which are characteristic change in the value of the output variable
resistance and the capacitor's capacitance. of specic devices and as such constant. of a force or torque sensor. From experi-
As a sufciently high insulation resistance The stability of charge calibrators must be ence, it is two or three times the rms value
leads to a very high time constant, the considered in evaluating the calibration of the signal noise. This noise consists
problem of discharge only affects very results. of the background noise of sensor and
long measuring periods. Given the drift amplier.
characteristics of charge ampliers are well
known from extensive research, the peak
value can be used to evaluate the effect of
drift on the calibration result.

www.kistler.com 19
Cutting Force Measurement during Turning

Forces during longitudinal cylindrical turning Turning with dynamometer Type 9129A...

Turning is machining with a geometrically Cylindrical turning is the model situation 100
Zoom on

defined cutting edge and a circular cut- of machining with a geometrically deter-
Fp [N]
80
Fc [N]

ting motion. Normally the workpiece car- mined cutting edge, and is particularly
60 Ff [N]

40
ries out the rotational movement. The suitable for determining the specific ma- 20

single-point tool (turning tool) is firmly chining force ki1,1 of materials. With uni- 0
2 4 6 8 10 12 14 16 18 20 22

clamped on the dynamometer for cutting versal lathes, stationary bench dynamo- 20 Time [s]

force measurement. meters are mounted on the tool slide in 40

60
place of the tool holder. The tool edge 80

The machining force produced by the must be accurately set to the workpiece 100

turning process is resolved directly into center.


Measured turning data
three significant components by the
multi-component dynamometer. For lathes with a turret-head style tool Material C45E
holder, the the 3-component measuring
Forces Measurable system Type 9129A... is used. The exact vc 495 m/min
During Turning position of the tool edge is ensured by the f 0,05 mm/rev.
tool holder fixture on the turret head. The ap 0,5 mm
Main cutting force Fc modular measuring system Type 9129A Dynamometer Type 9129A...
Feed force Ff accommodates different combinations of
lathe adapters and toolholders. All of the
Passive force Fp
popular types and sizes of adapter as well
as toolholders for boring and outside turn-
ing tools are available.

20 www.kistler.com
Cutting Force Measurement during Milling

Milling with stationary dynamometer Hard milling (56 HRC) with rotating dynamometer Forces during face milling
Type 9255B Type 9125A...

During milling, the rotating multiple-point The rotating cutting-force dynamometer 200.00
Fx [N]

tool carries out the cutting movement. is inserted into the spindle and holds the 160.00
Fy [N]
Fz [N]

With each tool rotation each cutting edge tool. The position of the tool edge with
120.00
is brought into contact once. As a result respect to the sensor is always the same.
of the interrupted cut, the cutting force at The rotating system is the only method 80.00

the cutting edge fluctuates according to of measuring the spindle torque during 40.00

the angle of contact and the number of milling. The following components are
0
cutting edges. measured: 1 2 3 4 5 6 7

40.00
Time [s]

There are two different ways of making Forces Measurable With


cutting force measurement during milling: Rotating Dynamometer Data measured during milling
During Milling
The workpiece to be machined is mount- Material C45E
Spindle moment Mz
ed on the top plate of an appropriately vc 34 m/min
dimensioned stationary multi-component Passive force Fp fz 0,065 mm
dynamometer. ap 4 mm
Forces Fx and Fy in the active
ae 4 mm
cutting plane
Forces Measurable With Tool Shank-type milling cutter
Stationary Dynamometer Diameter 6 mm
During Milling The DynoWare data acquisition software 3 cutting edges
enables the active force Fa or the tangen- Dynamometer Type 9257B
Feed force Ff tial force Ft and radial force Fr at the tool
(Force in the feed direction to be calculated.
of the tool)
Feed normal force Ffn
(Force perpendicular to Ff)
Passive force Fp

www.kistler.com 21
Cutting Force Measurement during Drilling

Forces during drilling Drilling with the rotating system Drilling with stationary dynamometer
Type 9125A... Type 9272

Drilling, countersinking, reaming and tap- With stationary dynamometers, the 5.00 Mz [Nm]

ping all use a similar machining process. workpiece is mounted on the top plate of 4.00

The tools are mostly multiple-point cut- the stationary dynamometer. It is essential
3.00

2.00

ting tools. for the machining to be kept in the center 1.00

of the dynamometer at all times. A suit- 0


1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3

For analyzing the drilling process the fol- able work holding fixture must be used to -1.00 Time [s]

1200.00 Fz [N]

lowing forces are of particular interest: ensure that the workpiece is appropriately 1000.00

repositioned for each new machining op- 800.00

Forces Measurable eration.


600.00

400.00
During Drilling 200.00

Rotating systems offer great advantages 0


1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3

Drilling moment Mz -200.0

for cutting force measurement. The drill-


Time [s]

Feed force Ff ing moment and feed force can be mea- Data measured during drillling
sured precisely, regardless of the size of
Deective forces Fx, Fy
the workpiece and the drilling position. Material Aluminum
Tool Twist drill
Deflective forces Fx, Fy perpendicular to Measuring torque during machining plac- Diameter 8,5 mm
the rotary axis provide additional informa- es great demands on the measuring in- Dynamometer Type 9125A...
tion on the machining process. strument. vc 1 400 m/min
f 0,4 mm/rev.
Depending on requirements, two different n 15 000 1/min
types of measurement can be used for
measuring the cutting force during drill-
ing:

22 www.kistler.com
Cutting Force Measurement during Grinding

Creepfeed grinding with force plate Lateral grinding of silicium workpieces with Cutting force during face grinding
Type 9253B23 dynamometer Type 9256C1

Grinding is cutting with geometrically The dynamometer is mounted on coordi- 2.0


Ft(x) [N]
non-defined tool angles. nate tables of face or profile grinding ma- Fa(y) [N]
Fn(z) [N]
1.6
chines. The workpiece is mounted on the
Stationary multi-component dynamo- dynamometer top plate. 1.2

meters are mainly used for measuring cut-


0.8
ting forces during surface grinding. They When the surface to be machined is par-
are suitable both for measuring small allel with the surface of the dynamometer 0.4

forces during oscilating grinding and for top plate, the following force components 0

large forces during full-width grinding. of the grinding wheel can be measured:
-0.4
2 4 6 8 10 12 14 16 18
Time [s]

Forces Measurable Data measured during grinding


During Grinding
Material Silicium
Tangential force Ft Tool Cup wheel
Dynamometer Type 9256C1
Normal force Fn
vc 2 340 m/min
Axial force Faxial vf 60 mm/min
ap 0,3 mm

www.kistler.com 23
Cutting Force Measurement for Special Applications

Evaluation of the new powerful machi-


ning processes requires appropriate sen-
sors.

Precision machining requires force measu-


ring instruments that will provide reliable
and accurate measurement of forces in
the Newton range. In practical terms, this
means sensors with higher sensitivity. Mi-
niDyn Type 9256C is designed with spe-
cial sensors whose sensitivity is three
times greater than that of quartz.

There are two requirements for analyzing


the high-speed machining process:

1. Rotating systems for high speeds.


HS RCD Type 9125A... measures
cutting forces reliably up to
25 000 1/min.
High-speed milling of aluminum with Measurement of forces and torques when
2. MiniDyn Type 9256C has an extra light dynamometer Type 9256C2 drilling the central bore in quartz washers with
titanium top plate and reaches natural Type 9272
frequencies of over 5 kHz in all three
force components.
80
3
Fz [N] Fx [N] Fy [N]
Mz [Nm]
The unconventional design of dynamo-
60
2.5
40
meter Type 9129AA and MiniDyn Type 20
2

9256C provide a low structural height 0 1.5

(32 mm respective 25 mm) as well as a -20


1
-40
small temperature error in all three axes. -60
0.5

-80 0

-100 -0.5
0,50 0,502 0,504 0.506 0.508 0.51 2.35 2.375 2.4

Time [s]
Time [s]

Data measured during high-speed milling with Data measured during high-speed milling
Type 9256C2 with Type 9125A...

Material Hardened steel HRC 56 Material Aluminum


Tool Carbide spherical Tool End mill 10 mm
end-milling cutter, r = 1 mm, n 22 281 1/min
twin cutters vc 700 m/min
n 50 000 1/min vf 6 684 mm/min
vf 40 mm/s ap 4 mm
ap 0,3 mm ae 10 mm
ae 0,3 mm

24 www.kistler.com
Torque Measuring during Machining

3 Methods
Rotating dynamometer Stationary dynamometer Stationary multi-component dynamo-
with torque sensor with torque sensor meter with calculated torque

Rotating torque sensor Stationary torque sensor Calculated torque

Measuring torques on rotating tools provi- The stationary 4-component dynamome- Stationary dynamometer Types 9129AA,
de useful data in cutting force measure- ter Type 9272 is also suitable for measu- 9253B, 9255B, 9256C..., 9257B and
ment. ring the torque during drilling. 9265B provide special solutions for
measuring the torque during drilling.
The ideal measuring instruments for this In order to prevent measuring errors, the
are the rotating measuring systems (Types drilling position must always be in the The drilling moment Mz is thereby calcula-
9123C..., 9124B..., 9125A...). The center center of the dynamometer, in other ted from the components of the reaction
of the rotating tool is located in the refe- words the reference point of the torque forces Fx and Fy. This requires at least five
rence point of the moment measuring measuring system. charge amplifiers and the DynoWare data
system. acquisition software.
Torque measurement is then not indepen-
The torque of the rotating tool will then dent of the machining position as with a The drilling torque Mz is calculated with
always be correctly measured no matter rotating dynamometer. either an 8-channel charge amplier with
what the machining position is. summing calculator or in DynoWare data
acquisition software.

The rotating measuring system is Torque measurement with the stationary Torque measurement is only possible
suitable for torque measurement during system is only possible during drilling. during drilling and is not suitable for
drilling and milling. demanding tool wear analyses. The
coordinates of the drilling position must
be entered in the software before data
acquisition.

www.kistler.com 25
Dynamometer Selection Table

Kistler offers a comprehensive range of Dynamometers particularly designed for a When measuring cutting forces, the prin-
measuring equipment. Some dynamome- specific machining method are indicated ciple of the 6-component force and mo-
ters are universal and can be used for var- by a blue field. The dynamometer can al- ment measurement only applies to a few
ious tasks. Others were developed for a so be used for applications indicated by a dynamometers. The machining method is
specific measuring task or a particular ma- gray field. In these cases there may be li- restricted to drilling. By using the Dyno-
chining method. mitations, for example regarding accuracy Ware evaluation software, the spindle
or dynamic behavior. moment Mz can be calculated for a dril-
The table below will help the user to ling position to be defined. Dynamome-
choose the right device. ters that can measure torques directly are
preferable for determining wear values on
drilling tools.

Dynamometer Process
Turning Milling Drilling Grinding
outside outside inside
Cut Cut Cut Cut
heavy light light heavy light heavy light heavy light

Type Components stationary rotating

9123C... Fx, Fy, Fz, Mz X

9124B... Fx, Fy, Fz, Mz X

9125A... Fz, Mz X

9129AA Fx, Fy, Fz X Mz

9129A... Fx, Fy, Fz X

9253B... Fx, Fy, Fz X Mz

9255B Fx, Fy, Fz X Mz Mz

9256C... Fx, Fy, Fz X Mz

9257B Fx, Fy, Fz X Mz

9257BA Fx, Fy, Fz X

9265B Fx, Fy, Fz X Mz

9272 Fx, Fy, Fz, Mz X

Dynamometer suitable Measurement possible with restrictions

heavy/light Do not exceed maximum Mz Spindle torque calculated


dynamometer load

26 www.kistler.com
Measuring
Stationary Dynamometer
Multi-Component Dynamometer with Top Plate 90x105 mm up to 10 kN
Specifications Type 9129AA
W Measuring range Fx, Fy, Fz kN 10 ... 10
Fz L
Fx Calibrated measuring Fx, Fy, Fz kN 0 ... 0,1
ranges kN 0 ... 1
H kN 0 ... 10
Sensitivity Fx, Fz pC/N 8
Fy pC/N 4,1
Fy
Natural frequency fnx kHz 3,5
fny kHz 4,5
Type 9129AA fnz kHz 3,5
Operating temperature range C 0 ... 70
LxWxH mm 90x105x32
Weight kg 3,2
Degree of Protection IEC/EN 60529 IP67 with connected cable
Connection Fischer Flange 9-pole neg.

Characteristics Applications Accessories


This sensor is calibrated and The low prole, large measuring Measuring cutting forces involved Connecting cable
ready for measurement. range and small temperature error in milling and grinding. - Type 1687B5/1689B5
make this dynamometer the ideal (3-Comp.)
instrument for measurements on - Type 1677A5/1679A5
precision machinery. Its design (6-Comp.)
ensures high natural frequencies in
all three force directions. Data sheet 9129AA_000-709

Multi-Component Force Plate with Top Plate 400x600 mm in Steel up to 30 kN


Specifications Type 9253B22 Type 9253B23
W Fz L Measuring range Fx, Fy, kN 15 ... 15 12 ... 12
Fx Fz kN 15 ... 30 12 ... 25
H Calibrated measuring Fx, Fy kN 0 ... 15 0 ... 12
ranges kN 0 ... 1,5 0 ... 1,2
Fz kN 0 ... 30 0 ... 25
Fy kN 0 ... 3 0 ... 2,5
1)
Type 9253B22
Sensitivity Fx, Fy pC/N 7,8 7,8
Fz Fz pC/N 3,7 3,7
W Natural frequency fnx Hz 580 610
L fny Hz 550 570
Fx fnz Hz 720 570
H Operating temperature range C 20 ... 70 20 ... 70
LxWxH mm 600x400x100 600x400x100
Fy Weight kg 90 85
Type 9253B23 2) Degree of Protection IEC/EN 60529 IP67 with connected cable
Connection Fischer Flange 9-pole neg.

Characteristics Applications Accessories


This sensor is calibrated and With a top plate size of Cutting force measurement during Connecting cable
ready for measurement. 400x600 mm, large workpieces milling and grinding of large - Type 1687B5/1689B5
can also be securely mounted. The workpieces. (3-comp.)
measuring plate is mounted on the - Type 1677A5/1679A5
machine table through the center (6-comp.)
of the four feet.
Data sheet 9253B_000-146

1)
Top plate with tapped hole
M10x18
2)
Top plate with T-grooves
10H12

www.kistler.com 27
Measuring
Stationary Dynamometer
Multi-Component Dynamometer with Top Plate 260x260 mm up to 40 kN
Fz Specifications Type 9255B
Measuring range Fx, Fy kN 20 ... 20
L W Fz kN 10 ... 40
Fx Calibrated measuring Fx, Fy kN 0 ... 20
ranges kN 0 ... 2
Fz kN 0 ... 40
H kN 0 ... 4
Fy Sensitivity Fx, Fy pC/N 8
Fz pC/N 3,7
Natural frequency fnx kHz 2
fny kHz 2
fnz kHz 3,3
Operating temperature range C 0 ... 70
Type 9255B LxWxH mm 260x260x95
Weight kg 52
Degree of Protection IEC/EN 60529 IP67 with connected cable
Connection Fischer Flange 9-pole neg.

Characteristics Applications Accessories


This sensor is preloaded Rugged dynamometer ideal for Cutting force measurement during Connecting cable
and calibrated. heavy machining. For better cou- milling and grinding. - Type 1687B5/1689B5
pling of the base plate to the ma- (3-comp.)
- Type 1677A5/1679A5
chine table, the dynamometer can
(6-comp.)
additionally be fixed through the
center of the four sensors. This Data sheet 9255B_000-148
achieves a higher natural frequen-
cy of the measuring arrangement.

MiniDyn: Multi-Component Dynamometer up to 250 N


Fz Specifications Type 9256C1 Type 9256C2
Measuring range Fx, Fy, Fz N 250 ... 250 250 ... 250
L W Calibrated measuring Fx, Fy, Fz N 0 ... 250 0 ... 250
Fx ranges N 0 ... 25 0 ... 25
Sensitivity Fx, Fz pC/N 26 26
H Fy pC/N 13 13
Natural frequency fnx, fny, fnz kHz 5 4
Fy
Operating temperature range C 0 ... 70 0 ... 70
LxWxH mm 80x39x25 80x55x25
Weight g 750 870
Type 9256C2
Degree of Protection IEC/EN 60529 IP67 with connected cable
Connection Fischer Flange 7-pole neg.

Characteristics Applications Accessories


This sensor is preloaded The dynamometer with the small- Cutting force measurement in pre- Connecting cable
and calibrated. est mounting dimensions. The top cision machining, wafer-cutting, - Type 16897A5 (3-comp.)
plate is made of titanium. This grinding of hard disk read heads, - Type 1696A5 (5-comp.)
Tool holder Type 9402
achieves natural frequencies of diamond-turning, high-speed ma-
over 5 kHz in all three force direc- chining, ultra-precision machining
Data sheet 9256C_000-484
tions. The extremely high sensitivi- of brittle-hard materials.
ty (three times higher than that of
quartz dynamometers) means that
very small machining forces can be
reliably measured.

28 www.kistler.com
Measuring
Stationary Dynamometer
Multi-Component Dynamometer with Top Plate 100x170 mm up to 10 kN
Fz Specifications Type 9257B
Measuring range Fx, Fy, Fz kN 5 ... 5
Fz kN 5 ... 10 (Range during turning, with force applied
W according specification. Fx and Fy 0,5 Fz)
L Fx
Calibrated measuring Fx, Fy kN 0 .... 5; 0 ... 0,5; 0 ... 0,05
range Fz kN 0 ... 10; 0 ... 1; 0 ... 0,1
H
Sensitivity Fx, Fy pC/N 7,5
Fy Fz pC/N 3,7
Natural frequency fnx, fny kHz 2,3
fnz kHz 3,5
Type 9257B Operating temperature range C 0 ... 70
LxWxH mm 170x100x60
Weight kg 7,3
Degree of Protection IEC/EN 60529 IP67 with connected cable
Connection Fischer Flange 9-pole neg.

Characteristics Application Accessories


This sensor is calibrated and The universal dynamometer. Its Cutting force measurement Connecting cable
ready for measurement. handy size and ideal measuring during turning, milling or - Type 1687B5/1689B5
range for many applications have grinding. (3-comp.)
- Type 1677A5/1679A5
made the Type 9257B one of the
(6-comp.)
most popular multi-component
Tool holder Type 9403
dynamometers.
Data sheet 9257B_000-151

3-Component Dynamometer with Built-in Charge Ampliers up to 10 kN


Fz Specifications Type 9257BA
Measuring range Fx, Fy, Fz kN 5 ... 5

W Range 1 Fx, Fy kN 0,5 ... 0,5


L Fx Fz kN 1 ... 1
Range 2 Fx, Fy kN 1 ... 1
H Fz kN 2 ... 2
Fy
Range 3 Fx, Fy kN 2 ... 2
Fz kN 5 ... 5
Range 4 Fx, Fy kN 5 ... 5
Fz kN 5 ... 10 (Force applied according specifications;
for Fx and Fy 0,5 Fz)
Type 9257BA Sensitivity Fx, Fy mV/N 10
Fz mV/N 5
Natural frequency fnx, fny kHz 2,0
fnz kHz 3,5
Operating temperature range C 0 ... 60
LxWxH mm 170x100x60
Weight kg 7,4
Degree of Protection IEC/EN 60529 IP67
Connection MIL connector 14-19

Characteristics Application Accessories


This sensor is calibrated and The successful model in a version Cutting forces during turning, mill- Control unit Type 5233A1
ready for measurement. with integral three-channel charge ing, grinding. Tool holder Type 9403
amplifier. The low-impedance con-
Data sheet 9257BA_000-150
necting cable is permanently inte-
grated in the dynamometer. The
Control Unit Type 5233A1 makes
this measuring instrument ex-
tremely easy to operate.

www.kistler.com 29
Measuring
Stationary Dynamometer
Multi-Component Dynamometer with Tool Holder or Clamping Plate up to 30 kN

Fz Specifications Type Type

W 9265B with 9265B with


L 9441B 9443B
Fx Measuring range Fx, Fy kN 15 ... 15 15 ... 15
Fz kN 0 ... 30 10 ... 30
Calibrated measuring Fx, Fy kN 0 ... 15 0 ... 15
H Fy ranges kN 0 ... 1,5 0 ... 1,5
Fz kN 0 ... 30 0 ... 30
kN 0 ... 3 0 ... 3
Sensitivity Fx, Fy pC/N 8 8
Fz pC/N 3,7 3,7
Natural frequency fnx, fny kHz 1,5 1,7
fnz kHz 2,5 2,7
Type 9265B & 9441B Operating temperature range C 0 ... 70 0 ... 70
LxWxH mm 175x100x126 203x135x100
Weight kg 20 19,8
Degree of Protection IEC/EN 60529 IP67 with connected cable
Connection Fischer Flange 9-pole neg.

Characteristics Application Accessories


This sensor is calibrated and The cutting force dynamometer Cutting forces during turning, mil- Connecting cable
ready for measurement. with integral cooling channels for ling or grinding. - Type 1687B5/1689B5 (3-comp.)
temperature-stable measurement. - Type 1677A5/1679A5 (6-comp.)
Tool holder Type 9441B for
The basic unit must only be used
cutting tools max. 32x32 mm
in conjunction with the steel hold-
Clamping plate Type 9443B
er Type 9441B (for turning) or
with the clamping plate Type Data sheet 9265B_000-152
9443B (for milling or grinding).

4-Component Dynamometer for Cutting Force Measurement in Drilling


D Specifications Type 9272
d Measuring range Fx, Fy kN 5 ... 5
Fz Fz kN 5 ... 20
Mz Nm 200 ... 200
Mz Calibrated measuring Fx, Fy kN 0 ... 5
ranges 0 ... 0,5
Fx
Fz kN 0 ... 20
0 ... 2
Mz Nm 0 ... 200
0 ... 20
H Fy Sensitivity Fx, Fy pC/N 7,8
Fz pC/N 3,5
Mz pC/Ncm 1,6
Natural frequency fnx, fny kHz 3,1
fnz kHz 6,3
fn (Mz) kHz 4,2
Type 9272 Operating temperature range C 0 ... 70
DxdxH mm 100x15x70
Weight kg 4,2
Degree of Protection IEC/EN 60529 IP67 with connected cable
Connection Fischer Flange 9-pole neg.

Characteristics Applications Accessories


This sensor is calibrated and The stationary 4-component mea- Cutting force measurement Connecting cable
ready for measurement. suring instrument for cutting force during drilling. For training - Type 1679A5 (4-comp.)
measurements during drilling. The purposes, this instrument can also Tool holder Type 9404
through-hole in the center of the be used in cutting force measure-
Data sheet 9272_000-153
dynamometer enables shafts to be ments during milling, grinding or
inserted for torque measurements, turning.
for example.

30 www.kistler.com
Measuring
Stationary Dynamometer
Multi-Component Sensor Kit for Force Measurement up to 72 mm 25 ... 60 kN
Fz Specifications Type 9366CC...
Measuring range Fx, Fy kN 25 ... 25 *)
Fz kN 25 ... 60 *)
Fx Calibrated measuring Fx, Fy kN 0 ... 25
H ranges kN 0 ... 2,5
Fz kN 0 ... 60
Fy
kN 0 ... 6
D Sensitivity Fx, Fy pC/N 7,8
Fz pC/N 3,8
Natural frequency fnx, fny, fnz Hz 200 ... 1 600 *)
Operating temperature range C 20 ... 70
DxH mm 72x90
Weight kg 7
Degree of Protection IEC/EN 60529 IP67 with connected cable
Type 9366CC... Connection Fischer Flange 9-pole neg.

Characteristics Application Accessories


This sensor is preloaded This ready-to-connect and Cutting force measurement Connecting cable
and calibrated. calibrated multi-component kit during milling and grinding. - Type 1687B5 (3-comp.)
allows the user to assemble multi- - Type 1677A5 (6-comp.)
component measuring plates. Top
Data sheet 9366CC_000-681
plate sizes from 300x300 mm to
900x900 mm are possible.

*)
depending on material and size of the top plate

3-Component System for Measuring Cutting Forces up to 8 kN During Turning


Specifications Type 9129A...
Fy
Measuring range, Fx, Fz kN 5 ... 5 *)
max. allowable Fy kN 8 ... 8 *)
Calibrated measuring Fx, Fz N 0 ... 5; 0 ... 0,5
ranges Fy N 0 ... 8; 0 ... 0,8
Sensitivity Fx, Fz pC/N 8
L Fy pC/N 4,1
Fz Natural frequency fnx kHz 1,5 **)
fny kHz 1,5 **)
Fx fnz kHz 2,5 **)
W Operating temperature range C 0 ... 70
H
Clamping surface mm 90x105
LxWxH mm 150x107x63 *)
Type 9129A...
Weight kg 7,6 *)
Degree of protection IEC/EN 60529 IP67 with connected cable
Connection Fischer Flange 9-pole neg.

Characteristics Applications Toolholder for boring bar


This sensor is calibrated and This is a modular measuring Measuring cutting forces during Type 9129AF40
ready for measurement. system based on the dynamo- turning on turret lathes. Connecting cable Type 1687B5/
meters Type 9129AA with a 1689B5 (3-Comp.)
large measuring range. Its special Accessories
mounting arrangement ensures a Lathe adapter with straight Data sheet 9129A_000-710
small temperature error. The lathe shank (VDI) Type 9129AB...
adapter is readily mounted on the Lathe adapter with Capto C6
*)
dynamometer. The available tool- Type 9129AC6 Depending on adapter
**)
holders for lathe tools and boring Lathe adapter with clamping Applies to dynamometer Type
bars are equally easily mounted. wedge Type 9129AD... 9129AA with lathe type
Toolholder for lathe tool 9129AB40 and toolholder Type
Type 9129AE... 9129AE25, without tool

www.kistler.com 31
Measuring
Rotating Dynamometer
Rotating 4-Component Dynamometer RCS for Cutting Force Measurement up to 10 000 1/min
Specifications Type 9123C...
Measuring range FSO Fx, Fy kN 5 ... 5 *
Fz kN 20 ... 20
Mz Nm 200 ... 200
Speed 1/min 10 000 max.
Sensitivity Fx, Fy mV/N 2
H
Fz mV/N 0,5
Mz mV/Nm 50
Fy Natural frequency fnx, fny, fnz kHz 2
and fn (Mz)
Fx
Operating temperature range C 0 ... 60
D DxH mm 115x52
Mz Weight kg 3
Fz Degree of Protection IEC/EN 60529 IP67 with connected cable
Type 9123C... Signal transmission Non-contacting

Characteristics Applications Accessories


This sensor is calibrated and Various standard adapters (ISO 4-component force and moment Stator Type 5221B1
ready for measurement. 40, ISO 50, HSK). This adapter measurement. Cutting force mea- Cable Type 1500B19
is usually integrated with the surement at the rotating cutting Signal conditioner Type 5223B...
Tool adapter Type 9163
dynamometer. A tool adapter for edge during drilling and finish mill-
collet chucks is available for the ing.
Data sheet 9123C_000-121
tool holder. Internal cutting fluid
feed is possible. Signal transmission
is non-contacting and wear-free.
Max. spindle speed of
10 000 1/min.
* Depending on force application
point

Rotating 4-Component Dynamometer RCD for Cutting Force Measurement up to 5 000 1/min
Specifications Type 9124B...
Measuring range FSO Fx, Fy kN 20 ... 20 *
Fz kN 30 ... 30
Fy Mz Nm 1 100 ... 1100
Speed 1/min 5 000 max.
Sensitivity Fx, Fy mV/N 0,5
H Fz mV/N 0,33
Mz mV/Nm 9
Natural frequency fnx, fny, fnz kHz 1
Fx und fn (Mz)
Mz Operating temperature range C 0 ... 60
DxH mm 156x55
D
Fz Weight kg 7,5
Type 9124B... Degree of Protection IEC/EN 60529 IP67 with connected cable
Signal transmission Non-contacting

Characteristics Applications Accessories


This sensor is calibrated and A dynamometer with similar char- 4-component force and moment Stator Typ 5221B1
ready for measurement. acteristics to Type 9123C... The measurement. Cutting force mea- Cable Type 1500B19
max. speed is approx. 5 000 surement at the rotating cutting Signal conditioner Type 5223B...
Tool adapter Type 9165
1/min. For cutting force measure- edge during drilling and milling.
ments during heavy machining.
Data sheet 9124B_000-122

* Depending on force application


point

32 www.kistler.com
Measuring
Rotating Dynamometer
Rotating 2-Component Dynamometer HS-RCD for Cutting Force Measurement up to 25 000 1/min
Specifications Type 9125A...
Measuring range Fz kN 3 ... 3
Mz Nm 50 ... 50
Speed 1/min 25 000 max.
Sensitivity Fz mV/N 3
H Mz mV/Nm 185
Natural frequency fnz kHz 5
fn (Mz) kHz 2,5
Operating temperature range C 0 ... 60
DxH mm 74x105
Weight kg 1,5

D Degree of Protection IEC/EN 60529 IP67


Signal transmission Non-contacting
Mz

Characteristics Applications Accessories


Fz
Type 9125A... The 2-component dynamometer 2-component force-moment mea- The measuring system Type
for high-speed machining. surement for high-speed machin- 9125A... comprises rotor, stator,
A selection of adapters for all stan- ing, investigation of wear and cut- connecting cable and signal
conditioner
dard spindle capacities. Non-con- ting processes in milling and
Collet chuck Type 9169A...
tact signal transmission. Internal drilling.
cutting fluid feed is possible. Max. Data sheet 9125A_000-123
spindle speed of 25 000 1/min.

This sensor is calibrated and 1 2 3 4


ready for measurement.
Dynamometer Control Unit Analog Outputs Signal Conditioner for High Speed RCD
Type 5237

Power Measure

Sync. 1 ... 2 mm
Error

Command
Control

Range Fz
A-A
1

Mz
3

Fz Mz
RS-232C

az
Range Mz
A A
1

1
2 9 2
Mz
RCD 3
1 Fz
2 Mz Fz
9 GND

1 Rotor Type 9125A...


2 Stator Type 5235
3 Cable Type 1500A37 L = 8 m
4 Signal conditioner Type 5237A1/A2

www.kistler.com 33
Amplifying

Signal conditioning becomes particularly PCs are often used to acquire measure- it supports individual documentation of
important when measuring mechanical ment data. This imposes special require- measurement and saving of conguration
quantities such as force, strain and torque. ments on the functionality and user- and measured data.
Piezoelectric sensors output a charge friendliness of the software for visualizing
linearly proportional to the load acting on and evaluating the force signals. Kistler The sensor technology is constantly driven
the sensor. The charge amplier converts DynoWare is an easily used general- by microelectronic developments and
this charge into normalized voltage and purpose software package ideal for allows incorporation of the charge ampli-
current signals, which can then be eval- dynamometer force measurements with er right into the case of the sensor. This
uated in the in-line signal processing single- or multi-component force sensors. eliminates the need for sensor cables and
system. To meet practical industrial re- For signal analysis DynoWare offers the external signal conditioning.
quirements, Kistler offers a wide range of measurement technician online visualiza-
charge ampliers with different designs, tion of the measurement curves as well as
numbers of measuring channels, precision, useful calculation and graphics functions.
measuring ranges, sensitivity, bandwidth,
lter characteristics, scaling options and In addition to simple conguration of the
signal processing. most important measuring instruments,

Charge Amplier
Multi-Channel Charge Ampliers for Multi-component Force Measurement
Specifications Type 5080A...
Number of channels 2 ... 8
Measuring range FS pC 2 ... 2 200 000
Measuring range adjustment continuous
Frequency range (3 dB) kHz 0 ... 200
Output signal V 10
Supply voltage VAC 100 ... 240
VDC 11 ... 36
Input signal Type/ Piezoelectric, optional with
connector BNC neg.
Fischer 9-pole neg.
Type 5080A... Voltage, with
BNC neg.
Degree of protection to IEC/EN 60529 IP40
Interface RS-232C
USB 2.0
Case optional with
19" rack module (DIN 41494)
Desktop unit with support bracket
Available from 12/2009 Other features Display of mechanical measurands

Characteristics Applications Accessories


The parameters of this The outstanding characteristics of This charge amplier is employed RS-232C null modem cable,
charge amplier can be this charge amplier enable very for all aspects of cutting force l = 5 m, D-Sub 9-pol. pos./D-Sub
quickly and easily congured accurate measurement of even measurement. It is suitable for use 9-pol. neg. Type 1200A27
small forces. Each of the several with piezoelectric multi-compo- Connecting cable for signal
with the DynoWare soft- available variants of the individual nent dynamometers in the labora- outputs from charge amp to data
ware package for the PC. charge amplier module is pushed tory, research and development. acquisition card, l = 2 m
into the rack separately. This pro- D-Sub 15-pol. pos. / D-Sub
vides the user with an extremely 37-pol. neg. Type 1500B15A1
exible system upgradeable at any Inductive proximity switch
time to meet changing require- Type 2233B
ments.
Data sheet 5080A_000-744

34 www.kistler.com
Amplifying
Charge Amplier
Multi-Channel Charge Amplier for Multi-component Force Measurement
Technical data 5070Ax0xxx 5070Ax1xxx 5070Ax2xxx
Number of channels 4 8 8 with 6-component
summing calculator

General technical data


Measuring ranges FS pC optional 200 ... 200 000
600 ... 600 000
Measuring range adjustment continous
Frequency range (3 dB) kHz 0 ... 45
Output signal V 10
Type 5070A... Supply voltage VAC 100 ... 240
Input signal Type/connector piezoelectric, optional with
BNC neg.
Fischer 9-pole neg.
Degree of Protection to IEC/EN 60529 IP40
Interface optional RS-232C
RS-232C and IEEE-488
Case optional 19" cassette for rack mounting
Desktop unit with support bracket
19" cassette with panel mounting set
Other features
Display of peak values
Display of mechanical measurands

Characteristics Application Accessories


The parameters of this This amplier is ideal for multicom- The 4-channel amplier is effec- RS-232C null modem cable,
charge amplier can be ponent force-torque measurement tive for measuring cutting forces l = 5 m, D-Sub 9-pole pos. /
quickly and easily congured with piezoelectric dynamometers with Kistler dynamometers. The D-Sub 9-pole neg. Type 1200A27
or force plates for cutting force 8-channel amplier is suitable for Connecting cable for signal
with the DynoWare soft- measurement. 6-component force-torque mea- outputs from charge amp to data
ware package for the PC. surement in laboratories, research acquisition card, l = 2 m, D-Sub
and development. 15-pole pos./D-Sub 37-pole neg.
Type 1500B15
Connecting cable for signal out-
puts from 6-component summing
calculator to data acquisition card,
l = 2 m, D-Sub 15-pole pos. /
D-Sub 37-pole neg. Type 1500A7
Inductive proximity swith
Type 2233B

Data sheet 5070A_000-485

www.kistler.com 35
Analyzing
Software
DynoWare Type 2825A...

Technical data Windows Software for Data Acquisition and Evaluation


Supported charge amplifier: Type 5011/5015A.../5018A...
Type 5017/5019
Type 5070A...
Type 5080A...
Supported Signal Conditioners Type 5223B...
(for rotating dynamometers) Type 5237A...
More information see data sheet

Characteristics Applications Options


Simple operation, conguration Windows software for data acqui- None
and control of Kistler measuring sition and evaluation. All-purpose,
instruments via RS-232C interface, operator-friendly software, espe- Accessories
high-performance graphics, useful cially effective for force measure- Data acquisition card PCIM-DAS
Type 2825A signal evaluation and calculation ment with dynamometers and 1602/16 Type 2855A4
functions, simultaneous recording single- or multicomponent force Data acquisition card PC-Card-
of measuring channels. Is also ideal sensors. For signal analysis Dyno- DAS 16/16 Typ 2855A5
for acquisition and evaluation of Ware provides an online display Data acquisition box Type 5697
any physical measurands. of measurement curves as well Connecting cable Type 1500B15
as useful calculation and graphics Connecting cable Type 1500A67
functions. In addition to easy con- Connecting cable Type 1500B69
guration of the most important USB-RS232C converter
measuring instruments, DynoWare Type 2867
supports individual documenta-
tion of the measurement process
Data sheet 2825A_000-371
as well as storage of conguration
and measurement data.

36 www.kistler.com
Connecting
Connecting cable
Cables, High Insulation, Temperature Range 5 ... 70 C
Specifications Type 1677A5
Connection Fischer 9-pole pos.
Fischer 9-pole pos.
Length m 5
Diameter mm 12,3 (metal sheath)
Number of conductors 8

Type 1677A5 Used for 6-component measurement

Specifications Type 1679A5


Connection Fischer angle 9-pole pos.
Fischer 9-pole pos.
Length m 5
Diameter mm 12,3 (metal sheath)
Number of conductors 8

Type 1679A5 Used for 6-component measurement

Specifications Type 1687B5


Connection Fischer 9-pole pos.
Fischer 9-pole pos.
Length m 5
Diameter mm 12,3 (metal sheath)
Number of conductors 3

Type 1687B5 Used for 3-component measurement

Specifications Type 1689B5


Connection Fischer angle 9-pole pos.
Fischer 9-pole pos.
Length m 5
Diameter mm 12,3 (metal sheath)
Number of conductors 3

Type 1689B5 Used for 3-component measurement

Data sheet 1687B_000-545

www.kistler.com 37
Connecting
Connecting cable
Cables, High Insulation, Temperature Range 5 ... 70 C
Specifications Type 1696A5
Connection Fischer 7-pole pos.
Fischer 9-pole pos.
Length m 5
Diameter mm 8 (insulating plastic tube)
Number of conductors 6

Type 1696A5 Used for 5-component measurement for dynamometer


Type 9256C

Specifications Type 1697A5


Connection Fischer 7-pole pos.
Fischer 9-pole pos.
Length m 5
Diameter mm 8 (insulating plastic tube)
Number of conductors 3

Type 1697A5 Used for 3-component measurement for dynamometer


Type 9256C

Data sheet 1687B_000-545

38 www.kistler.com
Connecting
Cable
Cables, Low-resistance
Specifications Type 1500A7
Connection D-Sub 15-pole pos.
D-Sub 37-pole pos.
Length m 2
Diameter mm 7
Number of conductors 9
Used for Connection of summing amplifiers Type 5070Ax2xxx to
Type 1500A7 Type 2855A4

Specifications Type 1500B15


Connection D-Sub 15-pole pos.
D-Sub 37-pole pos.
Length m 2
Diameter mm 7
Number of conductors 9
Used for Connection of Types 5070A, 5223B..., 5237A... to
Type 1500B15 Type 2855A4

Specifications Type 1500A67


Connection 8 x BNC pos.
D-Sub 37-pole neg.
Length m 2
Diameter mm 9,5
Number of conductors 8
Used for Connection of BNC neg. outputs to Type 2855A4
Type 1500A67

Specifications Type 1500B69


Connection D-Sub 37-pole pos.
50-pole pos.
Length m 1
Diameter mm Flat cable
Number of conductors 50
Used for Connection of Types 1500A7, 1500B15 to
Type 1500B69 Type 2855A5 (PC card)

Data sheet 2825A_000-371

www.kistler.com 39
Accessories
Electronic Accessories
Distributing Box, Fischer 9-pole neg. 8 x BNC neg.
Specifications Type 5405A
Input signal Fischer 9-pole neg.
Output signal 8 x BNC neg.
Dimensions LxWxH mm 73x99x33

Type 5405A

Distributing Box, Fischer 9-pole neg. 3 x BNC neg.


Specifications Type 5407A
Input signal Fischer 9-pole neg.
Output signal 3 x BNC neg.
Dimensions LxWxH mm 73x99x33

Type 5407A

40 www.kistler.com
Accessories
Electronics
Data Acquisition Card
Specifications Type 2855A4, PCIM-DAS 1602/16
Number of measuring channels 8 differential
PC bus PCI
Resolution Bit 16
Sampling rate, max. kS/s 100
Connection D-Sub 37-pole pos.

Data sheet 2825A_000-371


Type 2855A4

Data Acquisition Card


Specifications Type 2855A5, PC-CARD-DAS 16/16
Number of measuring channels 8 differential
PC bus PCMCIA, PC-CARD
Resolution Bit 16
Sampling rate, max. kS/s 100
Connection 50-pole neg.

Data sheet 2825A_000-371

Type 2855A5

Data Acquisition Box


Specifications Type 5697
Number of measuring channels 32
Resolution Bit 16
Sampling rate, max. (continuously adjustable in DynoWare)
with 1 channel kS/s 1 000
with 8 channels kS/s 125
with 16 channels kS/s 62,5
Interface to PC USB 2.0 Type B, female
Dimensions mm 208x70x250
Type 5697 Weight kg 2,5

Data sheet 5697_000-745


Available from 02/2010

www.kistler.com 41
Technical Literature

Special Prints and Application Brochures

Cutting Force Measurement Basics


Measuring the Cutting Force Measuring with Crystals 900-335
in Five-Axis Milling 20.162
Guide to the Measurement
Cutting Force Measurements of force 20.193
on Rotating Tools 20.163
Piezoelectric Theory 920-270
Measurement of Cutting Forces
in High-Precision Machining 20.176

New Cutting Force Dynamo-


meters for High-Precision
Machining 20.185

Kraftmessung bei der


Hoch- und Ultraprzisions-
Bearbeitung 20.202

Zerspankrfte unter
Kontrolle 20.206

New Rotating Dynamometer


for the Analysis of high speed
metal-cutting Processes 920-229

Advanced Machining Process


Analysis Experience with the
new Rotating High Speed
Dynamometer 920-335

H3 Kraftmessung in der
Metallzerspanungstechnik 920-347

Sensors and Signal Analysis


in High Performance Cutting 920-340

42 www.kistler.com
Product Overview According to Type Numbers

Type Page Type Page

1500A7 39 9123C... 32
1500A67 39 9124B... 32
1500B15 39 9125A... 33
1500B69 39 9129AA 27
1677A5 37 9129A... 31
1679A5 37 9253B22 27
1687B5 37 9253B23 27
1689B5 37 9255B 28
1696A5 38 9256C1 28
1697A5 38 9256C2 28
9257B 29
2825A... 36 9257BA 29
2855A4 41 9265B 30
2855A5 41 9272 30
9366CC... 31
5070Ax0xxx 35
5070Ax1xxx 35
5070Ax2xxx 35
5080A... 34
5405A 40
5407A 40
5697 41

Windows is a registered trademark of Microsoft Corporation.


Teflon and Kapton are registered trademarks of DuPont.

www.kistler.com 43
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