3D Printing-Based Machinability Dynamometer: Design, Production, and Testing Process
Abstract
Accurate measurement of cutting forces and torques during drilling operations is essential for evaluating tool performance, analyzing material machinability, and optimizing process parameters. To address this need, a special dynamometer device was designed, manufactured, and validated using low-cost 3D printing technology. The device’s CAD model was created in SolidWorks, and its structural adequacy was analyzed using the finite element method (FEM) in ANSYS. The body was fabricated by the fused filament fabrication (FFF) method, and measurements of axial force (Fz) and torque (Mz) were performed with two S-type load cells connected to an Arduino-based data acquisition system. Validation tests conducted under quasi-static conditions with a universal tensile-compression testing machine confirmed that the device provides reliable and repeatable measurement results, achieving an accuracy rate of 93%. In addition, FEM results showed that the system could safely operate beyond the intended static loading conditions. This study demonstrates that 3D printing can be effectively utilized in the development of low-cost and customizable machinability test systems.
Keywords
Dynamometer, Additive manufacturing, Drilling force, Moment measurement, Low-cost device
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