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Instruction Manual Rotating Cutting Force Dynamometer (RCD) Type 9170A… ä 9170A_002-660e-04.18...
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Instruction Manual Rotating Cutting Force Dynamometer (RCD) Type 9170A… ä 9170A_002-660e-04.18...
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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 obligation to notify any person or organization of such changes or improvements.
Rotating Cutting Force Dynamometer, Type 9170A... Content Introduction ........................... 5 Important notes ..........................6 General ..........................6 For your safety ........................6 Electromagnetic compatibility ....................7 Instructions on handling the devices ..................7 ...
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Content 5.2.2.1 Basic procedure for determining the Dynamometer load ........33 5.2.2.2 Dynamometer load with utilization of planar-fitting spindle adapters ....33 5.2.2.3 Dynamometer load with the utilization of taper shank machine adapters ... 35 ...
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Rotating Cutting Force Dynamometer, Type 9170A... 11.3.3.2 Technical data of the interface RS-232C ............. 67 11.3.3.3 Interface cable RS-232C ..................68 11.3.4 C ommand line ........................68 11.3.5 C ommand instruction set ....................69 ...
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 Accessories are used.
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...
Important notes Electromagnetic compatibility The rotating dynamometer Type 9170A..., stator Type 5236B and signal conditioner Type 5238B... is in full compliance with CE standards and fulfils the standards respecting Electromagnetic Compatibility (EMC) (see chapter 13). Instructions on handling the devices 2.4.1 Dynamometer The rotating dynamometer may be installed, operated and...
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 contained in these instructions may be changed at any time and without advance notification.
General system description General system description Purpose of the rotating Cutting Force Dynamometer The rotating cutting force dynamometer (RCD) is used for the dynamic and quasi-static measurement of the three Cartesian force components F and the torque M a rotating tool. Data transmission is accomplished with near field telemetry.
Rotating Cutting Force Dynamometer, Type 9170A... Components of the measurement system Fig. 2: RCD measurement system The system of the rotating Dynamometer Is comprised of: Dynamometer (rotor) with built-in charge amplifier and telemetry electronics (Type 9170A…) Stator with power supply and receiver (Type 5236B) ...
General system description 3.2.1 The rotating Dynamometer A 4-component sensor (F ) is built into the Rotating Dynamometer Type 9170A... that is built in using a hollow tension screw under high preload between machine adapter and the tool adapter. This is the prerequisite for the transfer of the friction forces for the measurement of the shearing forces F and F...
Conversion to a different spindle adapter is possible to only a limited extent and must in any event be carried out at the manufacturer's plant. Contact the Kistler representative in the event that a conversion to a different spindle adapter should become necessary.
Various manufacturers offer these collets. As an alternative, they can also be ordered directly from Kistler. Ultra-precision collets with the clamping range of 1 ... 20 mm are offered under the designation Type 9169A…. The assembly of the collet is described in chapter 4.3.
Rotating Cutting Force Dynamometer, Type 9170A... 3.3.4 Data acquisition with PC Kistler DynoWare Type 2825A… is a universal and easy to operate software for data acquisition and analysis. The configuration and control of the Signal Conditioner Type 5238B... are integrated in this software.
Installation and commissioning Installation and commissioning Important instructions The RCD Type 9170A… is a precision instrument that requires 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 20 000 rotations per minute for force and moment measurements (see chapter 11).
Rotating Cutting Force Dynamometer, Type 9170A... Installation situation of the system on the spindle head Spindle Mounting plate Spacer Stator Rotor (RCD) Clamping nut Collet Tool Fig. 6: Installation of the RCD and the stator mounting on the spindle head of the machine tool Page 16 9170A_002-660e-04.18...
Installation and commissioning Mounting the tool The tool is mounted prior to installation of the Rotating Dynamometer Type 9170A on the spindle. The clamping range of the collet DIN 6499-B32 (Type 9169A...) must match the nominal diameter of the tool. 4.3.1 Mounting the collet First, fit the notch of the collet DIN 6499-B32 in the...
Rotating Cutting Force Dynamometer, Type 9170A... 4.3.2 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.
Installation and commissioning Mounting the rotor (Dynamometer) Please observe the respective information in the manual of the machine tool manufacturer before the dynamometer is inserted in the spindle. The rotor must be manually inserted into the spindle; the use of the automatic tool changer to replace it is not permitted.
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Rotating Cutting Force Dynamometer, Type 9170A... Fig. 10: Stator mounting on machine tool spindle head Upper side of the stator: colored surface Fig. 11: Stator mounting on machine tool spindle head Page 20 9170A_002-660e-04.18...
Installation and commissioning Another possible mounting option consists of screwing the stator directly in the spindle head. This requires however that two threaded holes be placed in the spindle head. The remarks in chapter 4.4 are also to be taken into account with this variant.
Rotating Cutting Force Dynamometer, Type 9170A... 4.6.2 Wiring of signal conditioner with PC The Signal Conditioner Type 5238B… can be connected to a PC for the purpose of data transmission and measurement system control. Measurement signals: The measurement signals are present on the front side of the device at both the D-Sub plug and the BNC plugs.
Installation and commissioning Rotor detection The Signal Conditioner Type 5238B1 or Type 5238B2 detects the Rotor Type used (Type 9170A or Type 9171A). The associated filter cascade is activated accordingly. Fig. 12: Display of the selected low pass filter Using the remote control interface The measuring chain is controlled/triggered when the Remote Control plug is used.
Rotating Cutting Force Dynamometer, Type 9170A... Functional capability check If the measuring chain is completely installed and the devices are wired, then the measuring chain is ready for operation. The Signal Conditioner Type 5238B… can be switched on (power switch on the rear side of the device). The green LED Power Dynamometer on the front side of the device must be illuminated, the red LED Sync.
Installation and commissioning 4.11 Removing the rotating Dynamometer The rotor must be removed manually from the spindle; the use of the automatic tool changer to replace it is not permitted. If the stator is already mounted (see chapter 4.5), there is a risk of damaging both the stator and the tool changer.
Rotating Cutting Force Dynamometer, Type 9170A... Forces and loads Relationship of the effective forces 5.1.1 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.
Forces and loads 5.1.2 Relationship of the forces measured with an RCD and with a stationary Dynamometer In contrast to stationary dynamometers, the coordinate system 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...
Rotating Cutting Force Dynamometer, Type 9170A... 5.1.3 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 subject to direct comparison.
Forces and loads 5.2.1 Calculative determination of the Cutting Force F The fundamental dimension for the calculation of the cutting force F and of the normal cutting force F is the chip thickness h. = 0° Fig. 15: Fundamental dimensions during milling Fig.
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Rotating Cutting Force Dynamometer, Type 9170A... The chip width b is made up of the axial infeed a and the tool cutting edge angle together. According to Kienzle, the cutting force is based in simplified terms on the chip width b, the specific cutting force k (for benchmarks, see table 1) and the chip i1,1...
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Forces and loads Table 1: Median specific cutting forces and normal cutting 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 p1.1...
Rotating Cutting Force Dynamometer, Type 9170A... sin sin 0.05 sin 90° 2260 ; 1 (from Table1) ∙ ∙ 5 ∙ 2260 ∙ 0.05 5 ∙ 2260 ∙ 0.05 1387 If several cutting edges are in use simultaneously, then the load on the measuring element can be several times greater than with a single engaged cutting edge, as it is always loaded with the total of all of the forces.
Forces and loads 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 9170A 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 9170A;...
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Rotating Cutting Force Dynamometer, Type 9170A... In addition, however, the loading capacity limit of the dynamometer (red line in Fig. 18) may also not be exceeded (areas with gray backgrounds in Fig. 18). This could happen, particularly with large machine adapters (HSK-A80 and Capto C6).
Forces and loads 5.2.2.3 Dynamometer load with the utilization of taper shank machine adapters The loading capacity limit of the dynamometer (red line in Fig. 20) may not be exceeded under any circumstances (areas with gray backgrounds in Fig. 20). This could happen, particularly with large machine adapters of the 50 mm size.
Rotating Cutting Force Dynamometer, Type 9170A... 5.2.2.4 Reading example Machine adapter used: HSK-A80 Cantilever length az: 200 mm Fig. 22: Shear force vector F for az = 200 mm Result: If az = 200 mm, the planar fit would not be lost before the lifting force vector reaches F ≥2.8 kN;...
Forces and loads 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 parameters to reduce the shear force vector F .
Rotating Cutting Force Dynamometer, Type 9170A... 5.2.3 Avoiding overloading in everyday practice In order to avoid expensive repairs of the measurement system, it is important exercise caution with the first tests, particularly in cases where the respective load either cannot be estimated or can only be very poorly estimated beforehand.
Operation Operation Operating and display elements Switch for Selection of Low-Pass Filter Switch for Reset/Operate and Remote Control Sync. Error LED Power Supply LED for Signal Conditoner and Dynamometer Switch for Range Selection for F Signal Input (PCM) Connector: Binder 6 pol. neg. Signal Output (Analog) Connector: 4 x BNC neg.
Rotating Cutting Force Dynamometer, Type 9170A... Range selection Three ranges (1, 2 and 3) are available for measurement. Range 1 enables measurements with large forces/torques. Range 2 is required for the measurement of medium forces/torques. Range 3 is set when small forces/torques are to be acquired.
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 11.1). If however the dynamometer is installed in a machine tool spindle, then the natural frequencies of the machine spindle apply additionally.
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Rotating Cutting Force Dynamometer, Type 9170A... In order to avoid errors in the signal amplitudes, measurement must be carried out considerably below the natural frequency of the measurement setup. The following rule of thumb applies: For excess amplitude peaks <5 %, the excitation frequency (also referred to as the tooth passing frequency) may not amount to more than a maximum of f...
Operation Dynamic behavior of the RCD Particularly with heavy tools or ones with long projecting lengths, it is imperative that a frequency analysis be carried out prior to operating. The frequency analysis of the structure is exceptionally important for preventing damage to the RCD, tool, workpiece and the machine tool.
Rotating Cutting Force Dynamometer, Type 9170A... The sampling rate must be at least 10 000 Hz, the low pass filter frequency to the signal conditioner is to be set to the maximum value. -100 -150 Time / s Fig. 1: Typical signal for connection in y-direction Fast-Fourier-Transformation (FFT).
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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 … 360 Hz and 960 Hz … 1000 Hz. The speed of the tool must thus be selected in such a way that the tooth passing frequencies do not fall in these ranges.
Rotating Cutting Force Dynamometer, Type 9170A... Selecting the low pass filter The low pass filter is used to allow signal segments to pass practically unattenuated below their cutoff frequency, while at the same time attenuating or filtering out segments with higher frequencies. In the case of the RCD Type 9170A, three low pass filters installed signal...
Operation 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 chapter 7).
Rotating Cutting Force Dynamometer, Type 9170A... Influences on the measurement signals The measurement signals are impaired by a variety of influences. 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.
Influences on the measurement signals 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 vertical. If the vertical position is abandoned, then gravitation will have an effect on all force signals.
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Rotating Cutting Force Dynamometer, Type 9170A... In addition, the time of the "Operate" signal also has an influence. Two examples are shown in Fig. 29 and 30. Fig. 29: Signals of the radial forces F and F with horizontal rotation axis when "Operate" takes place at = 0°...
Influences on the measurement signals Influence of the temperature on the signals If temperature differences have an effect on the measurement system, then the measurement signal will also be influenced. The reaction of the z direction is particularly sensitive to temperature differences while the other directions are considerably more docile.
Rotating Cutting Force Dynamometer, Type 9170A... 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 (see chapter 3.3.3). 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.
Measurement signals 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 Rotating tool cutting edge and also experiencing the forces in effect during the cutting process.
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Rotating Cutting Force Dynamometer, Type 9170A... One exception is the position at which the coordinate system of the rotating dynamometer matches the fixed coordinate system ( = 90°). Force vectors for = 90° Fig. 33: Assuming that the x axis RCD (x ) is aligned precisely to the cutting edge, the following applies: ǀ...
Quality management systems, e.g. ISO 9001, require documentation of and compliance with periodic recali- brations of the measuring devices. Kistler recommends this type of recalibration every two years. Servicing tasks Please observe the following instructions for the servicing of your dynamometer: ...
Several possible malfunctions and their causes are listed in this chapter. The user can eliminate the causes of errors himself in some cases. If you are not able to eliminate a malfunction yourself, please contact the nearest Kistler representative. Malfunction...
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Eliminating malfunctions Malfunction Cause Elimination Dynamometer (green) The supply voltage for the Set stator distance from the rotor to either not illuminating or electronics in the Rotating 3 ... 8 mm and axial positioning. Do flickering. dynamometer is too low. not set up the stator in such a way that it covers an electrically conductive support (see chapter 4.5).
Contact the responsible Kistler representative and notify them of the shipping of the defective device. Send the defective dynamometer to the Kistler representative in the original packaging. Enclose an exact description of the defect and the accompanying circumstances with the dynamometer.
Technical data Technical data 11.1 Dynamometer Type 9170A (Rotor) 20 000 * Speed, max. 1/min Measurement range nominal –5 … 5 Single components, loads not simultaneous in their effects –20 … 20 N·m –150 … 150 Calibration range in the function of the spindle adapter see chapter 11.1.1 2...
Rotating Cutting Force Dynamometer, Type 9170A... 11.1.1 Calibration ranges in function of the spindle adapter Particularly in the case of smaller machine adapters, this limits the useful range of the rotating dynamometer. In the case of planar-fitting spindle interfaces (HSK and Capto adapters), the maximum bending moment may not exceed the limit value so that the rotor does not tip over and lose the planar contact.
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Technical data Calibration Calibration Calibration range 1 range 2 range 3 9170A221x Fx,Fy [N] 3 000 1 500 DIN ISO 7388-1 - AD40 Fz [N] 18 000 4 500 1 800 (DIN 69871-AD40) Mz [N·m] 9170A231x Fx,Fy [N] 4 500 1 800 DIN ISO 7388-1 - AD50...
Rotating Cutting Force Dynamometer, Type 9170A... 11.2 Transmission electronics Number of channels Number of ranges per channel Anti-Aliasing Filter Anti-Aliasing Anti-Aliasing Filter Type/Order Butterworth/6 Sampling rate per channel kS/s 22,2 Transfer rate (data) Mbps 1,25 Resolution 11.2.1 Time offset for transmission of the signals Page 64 9170A_002-660e-04.18...
Technical data 11.3 Signal conditioner Type 5238B… 0 … 10 Signal output (FSO) Number of channels Number of ranges per channel Low pass filter (switchable) 0,3 / 1,0 / 3,0 Tiefpass Low-Pass Filter Type/Order Butterworth/6 Output connector (analog signal) 4 x BNC neg. 15 pin D-Sub Interface for remote control RS-232C...
Rotating Cutting Force Dynamometer, Type 9170A... 11.3.3.3 Interface cable RS-232C Connection with Zero Modem Cable Type 1200A27 (not included in scope of delivery). Typ 5238B… Legend: = Transmit data = Receive data GND RS = Signal ground 11.3.4 Command line Several setting commands can be lined up per line with one another in any order.
Technical data 11.3.5 Command instruction set To start communicating, the CRn command must be sent to the signal conditioner first [Reset] / [Operate] Channel 1 ... 4 n = 0 Switchover to [Reset]; all Channels n = 1 Switchover to [Operate]; all Channels A short time delay is recommended before and after the RO command Range selection n = 0, 1, 2...
Rotating Cutting Force Dynamometer, Type 9170A... 11.4 Stator Type 5236B Dimension LxWxH 90x64x40 Radius (antenna) Weight Degree of protection DIN EN 60529 Plug Type Binder Serie 423 Pins 6 DIN pos. 11.5 Cable Type 1500A95 Length Diameter Weight Protection class DIN EN 60529 Plug Type Binder Serie 423...
Cable capacitance The cable capacitance, and thus the length of the connecting cable, has no noteworthy influence on the measuring result when Kistler special cables and Kistler charge amplifiers are used. Calibrated range Measuring range or part of the measuring range for which the sensor has been calibrated.
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Rotating Cutting Force Dynamometer, Type 9170A... Disturbance Quantity that is not the measurand but that affects the result 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: ...
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Repeated loading (1 … 3 times) of a calibration object prior to the calibration cycles applied for eliminating stresses within the object and/or for ensuring a rigid force application. quasistatic Describes the ability of Kistler sensors and charge amplifiers to undertake short-term measurements or DC-similar measurements. Range see "Measuring range"...
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Rotating Cutting Force Dynamometer, Type 9170A... 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.
Laboratory charge amplifier 1 %FSO Industrial charge amplifier Higher accuracy can be achieved with the following procedures: Calibration in the Kistler factory Calibration with charge amplifier Type 5395A Restriction of the temperature range Random errors, precision, reproducibility...
Errors due to zero drift caused by influences changing with time, such as the temperature, are thus basically excluded. With Kistler piezoelectric measuring chains, a typical repeatability within 0,1 %FSO can be assumed. 12.3...
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Annex Best straight line – mathematical definition The minimization of maximum deviation is known as Chebyshev’s approximation. The best straight line is determined as follows: x = measurand (reference) Q = sensor charge signal or output signal from the charge amplifier ...
Rotating Cutting Force Dynamometer, Type 9170A... 12.4 Frequency Range Because of their mechanical quality, piezoelectric sensors have very low damping. The useful frequency range is limited 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 error or achievable accuracy as a function of frequency:...
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 sensors are thus ideal for measuring measurands which change rapidly over time. Their dynamic behavior is thereby largely determined by the surrounding structure.
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Rotating Cutting Force Dynamometer, Type 9170A... Temperature gradient error (dynamic error) A temporary change in the output signal is denoted as temperature gradient error, when the temperature of the environment or surrounding medium changes with a certain rate. In this case, the sensor is not in thermal equilibrium with the environment.
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