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Kistler 9170B Series Instruction Manual

Rotating cutting force dynamometer (rcd)
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Instruction
Manual
Rotating Cutting
Force Dynamometer
(RCD)
Type 9170B...
9170B_012-021e-11.24

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Summary of Contents for Kistler 9170B Series

  • Page 1 Instruction Manual Rotating Cutting Force Dynamometer (RCD) Type 9170B… 9170B_012-021e-11.24...
  • Page 3 Foreword Information in this document is subject to change without notice. Kistler reserves the right to change or improve its products and make changes in the content without obliga- tion to notify any person or organization of such changes or improvements.
  • Page 4 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Content Introduction ........................... 5 Important notes ..........................6 General ..........................6 For your safety ........................6 Electromagnetic compatibility ....................7 Instructions on handling the devices ..................7 Dynamometer ........................7 Electronics ..........................8 Tips for using the instruction manual ..................
  • Page 5 Content Calculative determination of the Cutting Force F ............... 25 Determining the Dynamometer load ................... 29 5.2.2.1 Basic procedure for determining the Dynamometer load ........30 5.2.2.2 Dynamometer load with utilization of planar-fitting spindle adapters ....30 5.2.2.3 Dynamometer load with the utilization of taper shank machine adapters ..32 5.2.2.4 Reading example .....................
  • Page 6 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Annex ............................61 Glossary ..........................61 Measurement Uncertainty ....................65 Linearity ..........................66 Frequency Range ....................... 68 Influence of Temperature ....................69 Declaration of conformity ......................71 CE (Europe) ........................71 FCC (USA) .......................... 71 IC (Kanada) ........................
  • Page 7 It will help you with the installation, maintenance, and use of this product. To the extent permitted by law Kistler does not accept any liability if this instruction manual is not followed or products other than those listed under Components and Accessories in chapter 10.4 are used.
  • Page 8 Check all of the packaging of the device for transport  damage. Report any damage to the transport company and the responsible Kistler representative Work with the device should be carried out only under  the specified operating conditions; it should be pro-...
  • Page 9 Important notes Electromagnetic compatibility The rotating dynamometer Type 9170B... and the LabAmp WL Receiver Type 5347A... are CE-compliant and meet the standards for electromagnetic compatibility (EMC) (see chapter 13). Instructions on handling the devices Dynamometer The rotating dynamometer may be installed, operated and serviced only by persons who are familiar with the device and who are sufficiently qualified for their respective work.
  • Page 10 Please store this Instruction Manual in a safe place where it always ready at hand. If these instructions become lost, please contact your Kistler Customer Service Office and you will receive a replacement without delay. All of the information and directives con- tained in these instructions may be changed at any time and without advance notification.
  • Page 11 General system description General system description Purpose of the rotating Cutting Force Dynamometer (Inteded Use) The rotating cutting force dynamometer (RCD) is used for the dynamic and quasi-static measurement of the three Car- tesian force components F and the torque M on a rotating tool.
  • Page 12 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Components of the measurement system Fig. 3: RCD measurement system The rotating dynamometer system consists of: Dynamometer (rotor) with built-in charge amplifiers  and radio electronics (type 9170B..) Receiver dongle with USB extension cable ...
  • Page 13 General system description The Receiver Dongle The receiver dongle is the receiving and transmitting unit on the stationary side of the measuring system. The receiver dongle contains the transmitting and receiving antenna. The receiving antenna receives the data signals transmitted by the rotor and forwards them to the LabAmp WL Receiver.
  • Page 14 If the unit cannot be switched on after charging or if the state of charge is permanently below the permitted level of 25%, please contact Kistler Service. For storage of more than 3 months to less than 1 year, pro- ceed as follows: Regularly check the battery voltage at least every 6 ...
  • Page 15 3.2.4.3 Safety instructions Warning!  Do not attempt to remove the battery (battery can only be replaced by Kistler)  Do not dismantle the RCD  Do not expose to heat or flames  Do not short circuit  Do not drop or hit forcefully ...
  • Page 16 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Watchdogs A watchdog is a mechanism for detecting and correcting firmware malfunctions. The sensor has 2 watchdogs: System watchdog   Charging cable watchdog The sensor is automatically restarted when one of its watch- dogs triggers (detects a problem).
  • Page 17 Various manufacturers offer these collets. As an alternative, they can also be or- dered directly from Kistler. Ultra-precision collets with the clamping range of 1 ... 22 mm are offered under the desig- nation Type 9169A…. The assembly of the collet is de- scribed in chapter 4.2.1...
  • Page 18 Data acquisition software The Kistler PTS App type 2935A is a universal and easy-to- use software for data acquisition and evaluation. The con- figuration and control of the WL Receiver Type 5347A4 is integrated in this software.
  • Page 19 Installation and commissioning Installation and commissioning Important instructions The RCD Type 9170B… is a precision instrument that re- quires careful handling. The following instructions should be followed for that reason:  The dynamometer has been fine-balanced in order for it to be able to be used for up to 16 000 rotations per minute for force and moment measurements (see chap- ter 10).
  • Page 20 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Mounting the collet First, fit the notch of the collet DIN 6499-B32 in the eccen- tric ring of the clamping nut at the marked position. Tilt the collet chuck in the opposite direction until it audibly en- gages.
  • Page 21 Installation and commissioning Dismounting the collet After unscrewing from the holder, press on the front side of the collet while at the same time removing the collet from the engagement of the nut by applying transverse pressure to the rear part, across from the marking. Marking Fig.
  • Page 22  The rotor may only be inserted manually into the spindle without explicit approval from Kistler and may not be changed with the automatic tool changer. The dynamometer is installed in the machine tool spin- ...
  • Page 23 Removing the rotating Dynamometer The rotor may only be removed from the spindle manu- ally without explicit approval from Kistler and may not be inserted with the automatic tool changer. The measuring chain is to be switched off before the rotor is removed.
  • Page 24 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Forces and loads Relationship of the effective forces Cutting force and normal cutting force The coordinate system of a rotating dynamometer rotates along with the tool. This is to be taken into account when interpreting the forces.
  • Page 25 Forces and loads Relationship of the forces measured with an RCD and with a stationary Dynamometer In contrast to stationary dynamometers, the coordinate sys- tem rotates along with the rotating dynamometers. For this reason, the measurement signals of an RCD (F x,RCD ) cannot be compared directly with the measurement y,RCD...
  • Page 26 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Direct comparison of the forces measured with an RCD and stationary Dynamometer Because of the rotating coordinates, no direct comparison of the forces F and F by RCD and by stationary dynamometer is possible (see chapter 5.1.2). Only the active force is sub- ject to direct comparison.
  • Page 27 Forces and loads Calculative determination of the Cutting Force F The fundamental dimension for the calculation of the cut- ting force F and of the normal cutting force F is the chip thickness h. ϕ ϕ = 0° Fig. 13: Fundamental dimensions during milling κ...
  • Page 28 Rotating Cutting Force Dynamometer (RCD), Type 9170B… ���� ���� = ���� sin ���� According to Kienzle, the cutting force is based in simplified terms on the chip width b, the specific cutting force k (for i1,1 benchmarks, see table 1) and the chip thickness h and the tangent value of the angle of inclination m (for benchmarks, see table 1).
  • Page 29 Forces and loads Table 1: Median specific cutting forces and normal cut- ting forces in metal-cutting technology (according to W. Degner, H. Lutze, E. Smejkal: Chip Machining) Material Cutting Force F Normal Cutting Force F Passive Force F (1–m) (1-x) (1-y) c1.1 cN1.1...
  • Page 30 Rotating Cutting Force Dynamometer (RCD), Type 9170B… The greatest force occurs with the greatest chip thick- ℎ = ���� sin ���� sin ���� = ���� = 0.05�������� , i.e. with ϕ = 90° ness h ������������ ���� ���� ���� ���� = = 5��������...
  • Page 31 Forces and loads Determining the Dynamometer load Several forces have an effect on the RCD Type 9170B during processing. The important thing here is to ensure that the measuring device does not become overloaded, thus neces- sitating costly repairs. To calculate bending moments, it is the dimension az, i.e.
  • Page 32 Rotating Cutting Force Dynamometer (RCD), Type 9170B… 5.2.2.1 Basic procedure for determining the Dynamometer load Neither the load limit of the sensor in the interior of the RCD Type 9170B nor the maximum load of the spindle adapter may be exceeded during the machining. This is taken into account for the calibration of the Type 9170B;...
  • Page 33 Forces and loads The following picture shows the load limits of the dyna- mometer (red line with grey highlighted area) and the spin- dle adapter, which must not be exceeded. Fig. 16: Load diagram F If the shear force vector F = ((F is known, then the maximum axial force F can be read from...
  • Page 34 Rotating Cutting Force Dynamometer (RCD), Type 9170B… 5.2.2.3 Dynamometer load with the utilization of taper shank machine adapters The following picture shows the load limits of the dyna- mometer (red line with grey highlighted area) and the spin- dle adapter, which must not be exceeded. Fig.
  • Page 35 Forces and loads 5.2.2.4 Reading example  Machine adapter used: HSK-A63 Cantilever length az: 150 mm  Fig. 19: Shear force vector F for az = 150 mm Result: If az = 150 mm, the planar fit would not be lost be- fore the lifting force vector reaches F ≥2.0 kN.
  • Page 36 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Result: The RCD is overloaded when F >2.5 kN. The axial force is not permitted to exist when F = 2.5 kN (F 0 kN). It would make sense then to change the cutting pa- rameters reduce shear...
  • Page 37 Forces and loads Avoiding overloading in everyday practice In order to avoid expensive repairs of the measurement sys- tem, it is important exercise caution with the first tests, par- ticularly in cases where the respective load either cannot be estimated or can only be very poorly estimated beforehand. Basically there are two possibilities to choose from: 1.
  • Page 38 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Operation Operating and display elements The RCD has no status displays. All information about the status of the unit is provided by the LEDs of the WL receiver and by the status information in the software. Fig.
  • Page 39 Operation Usable frequency range of the mounted Dynamometer The natural frequencies of the Rotating dynamometer are high in all directions due to the preload of the sensor, the very rigid mechanical construction and the small size of the device (see chapter 10.1). If however the dynamometer is installed in a machine tool spindle, then the natural frequen- cies of the machine spindle apply additionally.
  • Page 40 Rotating Cutting Force Dynamometer (RCD), Type 9170B… In order to avoid errors in the signal amplitudes, measure- ment must be carried out considerably below the natural fre- quency of the measurement setup. The following rule of thumb applies: For excess amplitude peaks <5 %, the excitation fre- ...
  • Page 41 Operation Dynamic behavior of the RCD Particularly with heavy tools or ones with long projecting lengths, it is imperative that a frequency analysis be car- ried out prior to operating. The frequency analysis of the structure is exceptionally im- portant for preventing damage to the RCD, tool, workpiece and the machine tool.
  • Page 42 Rotating Cutting Force Dynamometer (RCD), Type 9170B… -100 -150 Time / s Fig. 25: Typical signal for connection in y-direction Fast-Fourier-Transformation (FFT). With the aid of the FFT, the signals are converted to the frequency range; this is nec- essary in order for it to be at all possible to determine which interference frequencies are to be avoided.
  • Page 43 Operation Afterwards, the frequency responses that were calculated with the help of the FFT are evaluated using graphs. All ranges in which a significant amplitude peak is visible are to be avoided. In the following example, these are the ranges 280 Hz …...
  • Page 44 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Signal conditioning The measuring signals are pre-processed in the measuring system as well as in the receiver by a two-stage signal con- ditioning. The first stage serves to ensure the Nyquist-Shan- non sampling rate and a measuring system-dependent digi- tal filtering.
  • Page 45 Operation 5 kS/Kanal  Fig. 29: Frequency response at 5 kS (left digital, right analogue) 10 kS/ Kanal  Fig. 30: Frequency response at 10 kS (left digital, right analogue) Low-pass filter In order to suppress any interfering signals, a further low-pass filter can be switched on by the user in the hardware setup of the software.
  • Page 46 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Sequence of a measurement Once all of the settings mentioned in chapter 4 have been made, the measurement system is ready for operation and the tool can be inserted in the tool adapter. Various effects influence the quality of the measurement signals (see chap- ter 7).
  • Page 47 Influences on the measurement signals Influences on the measurement signals The measurement signals are impaired by a variety of influ- ences. The objective is to minimize these influences in order to obtain measurement results that are as unambiguous and informative as possible. Influence of the speed on the signals The centrifugal forces that affect the sensor increase by the square of the spindle speed.
  • Page 48 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Influence of gravitation on the signals Gravitation has no influence on the signals for as long as the rotation axis of the rotor and thus also of the spindle is ver- tical. If the vertical position is abandoned, then gravitation will have an effect on all force signals.
  • Page 49 Influences on the measurement signals In addition, the time of the "Operate" signal also has an influence. Two examples are shown in Fig. 33 and 34. ϕ = 0° 90° 180° 270° 360° 450° 540° 630° 720° ϕ Fig. 33: Signals of the radial forces F and F with horizontal rotation axis when "Operate"...
  • Page 50 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Influence of the temperature on the signals If temperature differences have an effect on the measure- ment system, then the measurement signal will also be in- fluenced. The reaction of the z direction is particularly sen- sitive to temperature differences while the other directions are considerably more docile.
  • Page 51 Influences on the measurement signals Influence of internal coolant on the signals We recommend the use of the correct clamping nuts and sealing disks if the internal coolant is to be used If the internal coolant is used, then the rotor will, on the one hand, not only feel the load caused by temperature changes on the one hand (see chapter 7.3) but also by the prevailing pressure.
  • Page 52 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Measurement signals Interpretation of measurement signals When interpreting the measurement signals, it must be noted that the coordinate system also rotates with the tool. Thus it can be imagined that the user is sitting on the Rotat- ing tool cutting edge and also experiencing the forces in ef- fect during the cutting process.
  • Page 53 Measurement signals One exception is the position at which the coordinate sys- tem of the rotating dynamometer matches the fixed coordi- nate system (ϕ = 90°). ϕ Force vectors for ϕ = 90° Fig. 37: Assuming that the x axis RCD (x ) is aligned precisely to ǀ...
  • Page 54 Recalibration of the dynamometer is necessary after an un- controlled overload (see chapter 10), for example. This re- calibration should be performed at the manufacturer's plant. Please contact the responsible Kistler representative in such cases. Our products can be recalibrated or tested with the same procedure as was used prior to the initial delivery.
  • Page 55 If a major repair is necessary, you will receive a cost  estimate.  Kistler will it's best to repair your dynamometer in a short time and at minimum cost and send it to you in as-new condition. 9170B_012-021e-11.24 Page 53...
  • Page 56 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Technical data Dynamometer Type 9170B (Rotor) Speed, max. 1/min ≤16 000 Measurement range nominal –5 … 5 Single components, loads not simultaneous in their effects –20 … 20 N·m –210 … 210 Measuring Range 1 –0.5 …...
  • Page 57 Technical data Sampling rate per channel 2.5 / 5 / 10 Bandwidth ≈ 0 … 0.8 / 1.6 / 3.2 Resolution Battery life (active measurement) > 5 Supply voltage (charging) Battery charging time < 4 Max. storage time until recharge months Transmission type GFSK...
  • Page 58 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Calibration ranges in function of the spindle adapter Particularly in the case of smaller machine adapters, this lim- its the useful range of the rotating dynamometer. In the case of planar-fitting spindle interfaces (HSK and Capto adapt- ers), the maximum bending moment may not exceed the limit value so that the rotor does not tip over and lose the planar contact.
  • Page 59 Technical data LabAmp WL-Receiver Typ 5347A4… Number of channels Number of ranges per channel Digital low-pass filter ≥ 10 Cutoff-frequency (-3 dB) Selection in 1 Hz steps 1) Scaling analogue output ±10 Time shift analogue output 320 … 400 Output impedance typically Ω...
  • Page 60 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Time offset during transmission of the signals To ensure continuous measurement data output at the ana- logue outputs of the receiver, a buffer was integrated in the receiver that can safely bridge a transmission interruption of the data from the sensor to the receiver of <...
  • Page 61 Technical data Connector type D-Sub 9f Input level High (Reset, Stopp Trigger) >3.5 Input open Low (Measure, Start Trigger) <1 Max. input voltage ±30 Supply output V DC +24/±10% ≤200 Output current (short circuit proof) mA Receiver Dongle Outer dimensions LxWxH 51x19x11 Weight...
  • Page 62 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Components and accessories Components Type/Art. No. Rotor 9170B  Power supply* 5 V 55245931   Country-specific plug set 55255315 Magnetic charging cable to 55245928  power supply WL Receiver 5347A  Power supply* 24 V 5779A2 ...
  • Page 63 The cable capacitance, and thus the length of the connect- ing cable, has no noteworthy influence on the measuring result when Kistler special cables and Kistler charge ampli- fiers are used. Measuring range or part of the measuring range for which Calibrated range the sensor has been calibrated.
  • Page 64 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Disturbance Quantity that is not the measurand but that affects the re- sult of the measurement. The contributions are expressed in terms of the measurand related to the acting quantity. Examples: additional bending moment acts on a force sensor: →...
  • Page 65 Repeated loading (1 … 3 times) of a calibration object prior Prestress to the calibration cycles applied for eliminating stresses within the object and/or for ensuring a rigid force applica- tion. Describes the ability of Kistler sensors and charge amplifiers quasistatic to undertake short-term measurements or DC-similar meas- urements. Range see "Measuring range"...
  • Page 66 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Sensitivity Nominal value or calibrated value stated in the calibration certificate of the change in the response of a sensor divided by the corresponding change in the value of the measurand. Note: sensitivity of piezoresistive and strain gauge sensors is additionally dependent on the excitation current or voltage.
  • Page 67 ±0.2 ... 0.5 %FSO Laboratory charge amplifier ±1 %FSO Industrial charge amplifier Higher accuracy can be achieved with the following proce- dures: Calibration in the Kistler factory  Calibration with charge amplifier Type 5395A  Restriction of the temperature range ...
  • Page 68 Errors due to zero drift caused by influences changing with time, such as the tem- perature, are thus basically excluded. With Kistler piezoelectric measuring chains, a typical repeata- bility within 0,1 %FSO can be assumed. Linearity...
  • Page 69 Annex Best straight line – mathematical definition The minimization of maximum deviation is known as  Chebyshev’s approximation. The best straight line is de- termined as follows: x = measurand (reference)   Q = sensor charge signal or output signal from the charge amplifier Q (x) = calibration curve, rising and falling ...
  • Page 70 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Frequency Range Because of their mechanical quality, piezoelectric sensors have very low damping. The useful frequency range is lim- ited in the upwards direction by the increasing resonance rise. Key: f Measuring frequency Natural frequency Amplitude ratio The following approximate values apply to the amplitude...
  • Page 71 Annex In their dynamic behavior, piezoelectric sensors are superior to all other measuring methods. Their high rigidity results in the highest possible natural frequencies. Piezoelectric sen- sors are thus ideal for measuring measurands which change rapidly over time. Their dynamic behavior is thereby largely determined by the surrounding structure.
  • Page 72 Rotating Cutting Force Dynamometer (RCD), Type 9170B… Temperature gradient error (dynamic error) A temporary change in the output signal is denoted as tem- perature gradient error, when the temperature of the envi- ronment or surrounding medium changes with a certain rate.
  • Page 73 Declaration of conformity Declaration of conformity CE (Europe) Hereby, Kistler Instrumente AG declares that the radio equipment type 9170B... is in compliance with Directive 2014/53/EU. The full text of the EU declaration of conformity is available at the following Internet address: https://www.kistler.com/CH/en/cp/wireless-rotating-cut-...
  • Page 74 Rotating Cutting Force Dynamometer (RCD), Type 9170B… This device must accept any interference, including in-  terference that may cause undesired operation of the device Under Industry Canada regulations, this radio transmitter may only operate using an antenna of a type and maximum (or lesser) gain approved for the transmitter by Industry Canada.
  • Page 75 Declaration of conformity Japan Japanese Radio Law and Japanese Telecommunications Business Law Compliance: This device is granted pursuant to the Japanese Radio  Law (電波法) and the Japanese Telecommunications Business Law (電気通信事業法).  This device should not be modified (otherwise the granted designation number will become invalid).