Catalogo KISTLER Dinamometros

Analyzing and
optimizing cutting
processes
Cutting force
measurements in research
and development
High-precision measurement systems for metal-cutting
production
www.kistler.com
Absolute Attention for
tomorrow’s world
Kistler develops measurement solutions

consisting of sensors, electronics,
systems and services. In the physical
border area between emissions
reduction, quality control, mobility and
vehicle safety, we deliver excellence
for a future- oriented world and create
ideal conditions for Industry 4.0. We
thereby facilitate innovation and growth
for — and with — our customers.
Kistler stands for progress in motor Kistler measurement technology ensures Kistler systems support all steps of
monitoring, vehicle safety and vehicle top performance in sport diagnostics, networked, digitalized production and
dynamics and provides valuable traffic data acquisition, cutting force ensure maximum process efficiency
data for the development of the efficient analysis and other applications where and profitability in the smart factories of
vehicles of tomorrow. absolute measurement accuracy is the next generation.
required.
2 www.kistler.com
Contents
Fundamentals of cutting force measurement 4

Overview of dynamometers 6
Force and moment measurement 8

Stationary dynamometers 8
Rotating dynamometers 10
Cutting force measurement 12

Milling 12
Drilling 14
Turning 16
Grinding 18
Micromachining 19
Application examples 20
Products 23
Amplification, acquisition and evaluation

— all from one single source 38
The LabAmp family 40
Measuring chains 42
Charge amplifiers 44
Data acquisition system with integrated charge amplifier 45
Data acquisition system 46
Software 46
Connecting cables, high-insulation 48
Accessories 49
Additional sensors for frequency analyses 49
Kistler service: customized solutions from A to Z 50
At our customers’ service across the globe 51
www.kistler.com 3
Milling high-alloy steel with a Type 9255C dynamometer
Fundamentals of cutting force measurement

Metal-cutting is still the most important machining process, and Capturing highly dynamic forces in cutting processes
it provides the basis for technical products of all kinds. There Kistler’s piezoelectric sensors record highly dynamic processes
has been a constant increase in the requirements to be met by with optimum signal quality. They offer valuable insights into the
cutting processes and the products manufactured with them, actual process, providing the basis for reliable, productive and
resulting in major changes to this method of production over reproducible manufacturing processes.
recent decades.
Regardless of batch size, the manufactured products are

expected to offer convincing quality and they must be cost-
effective. Detailed knowledge of cutting processes is essential
in order to meet these requirements. Key indicators include
the acting forces and moments: if they are not known, it is
impossible to make any statements whatsoever about the
quality of the manufacturing process. The highly dynamic forces
that occur during a cutting process can only be measured and
analyzed with sensor systems developed on the basis of profes-
sional expertise, for use in the harsh environments where
machinery is operated.
4 www.kistler.com
Development and assessment of tools and materials Process analysis and optimization
•• Optimizing tools and clamping devices under real operational •• Analysis of cutting processes and targeted error/fault diagnosis
conditions •• Comparing and developing machining strategies
•• Assessing cooling lubricants •• Identifying unfavorable cutting situations
•• Determining the machinability of materials •• Identifying unused potentials: tool edge life and productivity
•• Verifying simulations and process models •• Identifying the influences of different material batches
•• Highlighting unique product characteristics
Processes
•• Turning, milling, drilling, sawing, screw tapping, broaching,
hobbing, and many others.
•• Grinding, honing, polishing, and many others.
Benefits of force measurement technology by Kistler

•• High rigidity and natural frequencies enable resolution of
individual cutting edge engagements
•• Measurement of three force directions and torque
•• Measurement range from micromachining to heavy-duty
cutting
•• Robust and resistant to coolants (IP67)
•• Simple to integrate and handle thanks to compact
structure
•• Extremely long service lifetimes
www.kistler.com 5
Overview of dynamometers
Stationary dynamometers Rotating dynamometers

A stationary dynamometer is often the connecting element Rotating dynamometers (RCDs) are inserted directly into the
between the machine tool’s table and the workpiece. The machine spindle via the spindle interface. The tool is mounted
workpiece is fixed on the dynamometer, enabling measurement on the RCD with the help of a tool holder. RCDs are mainly used
of reaction forces in production processes such as milling or in milling and drilling processes. RCDs differ from stationary
drilling. Stationary dynamometers can also be used for turning dynamometers in several ways: for example, only one multi-
applications. In this case, appropriate machine adapters are used component sensor is installed in an RCD to measure the moment
to position the dynamometers directly on the turret head. Then, directly on the tool. As well as the sensor, the rotor contains
the tool is positioned on the dynamometer with a suitable tool the charge amplifier and the telemetry electronics. Near-field
holder. Depending on the structure, the forces occurring are telemetry is used to transmit the measurement data to the
captured by one or more multi-component force sensors and stationary part of the measuring chain, where it is then made
are available at the dynamometer connector in the the form of available in the form of analog voltage signals.
charge signals.
6 www.kistler.com
Heavy-duty cutting
influences inimized
Micromachining
Drilling/thread
Temperature
components
Page
Measurable
Grinding
tapping
Turning
Milling
Type
Application
Rotating system for measurements

Fx, Fy, Fz, on the tool, at high speeds of up to
9170A no 34
Mz 20 000 rpm and small to medium
forces
rotating
Rotating system for large forces and

Fx, Fy, Fz,
9171A no speeds of up to 12 000 rpm, different 36
Mz
adapters provide excellent flexibility
The expert solution for

micromachining with forces below 1 N
9109AA Fx, Fy, Fz yes 23
and up to 500 N, and speeds of up to
160 000 rpm
Table-mounted system for precision

machining with forces of less than 1 N
9119AA1 Fx, Fy, Fz yes 24
up to 4 000 N and speeds of up to
60 000 rpm
The expert solution for precision

machining, suitable for table mounting
9119AA2 Fx, Fy, Fz yes 24
or as a modular system for mounting
on turning turrets
Best-seller and all-rounder for table

9129AA Fx, Fy, Fz yes mounting or as a modular system for 26
mounting on turning turrets
Compact solution for somewhat larger

9139AA Fx, Fy, Fz yes 28
forces (up to 30 000 N)
stationary
The classic model for table mounting

9257B Fx, Fy, Fz no 29
and forces of up to 10 000 N
Robust platform, optimized for

9255C Fx, Fy, Fz no medium to extremely large forces 30
(up to 60 000 N)
Solution for large workpieces with

9253B Fx, Fy, Fz no 31
workpiece-side measurement
The expert solution for drilling trials

Fx, Fy, Fz,
9272 no with direct torque measurement in the 32
Mz
center of the platform
Pre-loaded, ready calibrated set

9366CC Fx, Fy, Fz no of force sensors to set up custom 33
clamping solutions
suitable limited suitability
www.kistler.com 7
Stationary dynamometers:
force and moment measurements
Application
All stationary 3-component dynamometers share the same
advantage: they can be used both as a purely 3-component
dynamometer and also as a 6-component dynamometer. The
four 3-component force sensors inside the dynamometer are
switched as appropriate to make this possible. Forces Fx, Fy and
Fz are measured directly, whereas moments Mx, My and Mz
are calculated with the help of the individual force components
and sensor distances. Suitable adapters enable mounting of the
dynamometers on milling tables as well as lathe turrets.
Structure of a stationary dynamometer

The dynamometers consist of multi-component force sensors
mounted under high preload between two base plates and
a cover plate. Preloading is needed so that frictional forces can
be transmitted. Ground-isolated installation of the force sensors
largely eliminates ground loop problems. The dynamometers
meet the requirements for degree of protection IP 67; they are
rust-resistant and are protected against penetration by splash
water and coolants. Various mounting bores and tapped holes
on the cover plate open up numerous clamping options.
Stationary dynamometer measuring chain

The measuring chain for stationary dynamometers consists of
a sensor and a charge amplifier with a data acquisition box to
record the signals, or just one LabAmp (with a laboratory charge
amplifier and data acquisition box combined in one device).
Benefits of a stationary dynamometer

•• Stationary dynamometers can be used for a highly versatile
range of applications. For milling, drilling, turning or other
types of machining, the possibilities are virtually limitless
•• Thanks to piezo technology and robust geometry, large
dynamometers can also be used to measure small forces
•• When used correctly, Kistler’s dynamometers have
extremely long service lifetimes
8 www.kistler.com
3-core connecting cable
Fx
Fy
Fx1+2 Fz
a Fx3+4
Fy1+4
Fy2+3
Fz1 8-core connecting cable
Fz2 Fx1+2
Fz3 Fx3+4
a Fz4 Fy1+4
Fy2+3
Fz1
Fz2
Fz3
Fz4
b b
3-component force measurement 6-component force and moment measurement

In 3-component force measurement, the eight output In 6-component force and moment measurement, the eight
signals from the dynamometer are summed in the three-core output signals are fed directly to the eight charge amplifiers via
connecting cable (as shown in the illustration). Three charge the 8-core connecting cable. These amplifiers convert the charge
amplifiers are needed to convert the charge signals into propor- signals into proportional output voltages and they also calculate
tional output voltages. moments Mx, My and Mz, depending on the specification of the
charge amplifier.
Calculation of the three forces Fx, Fy, Fz Calculating forces and moments
and three moments Mx, My, Mz Kistler’s DynoWare software calculates the three forces (Fx,
Fy and Fz) and the three moments (Mx, My and Mz); the
Fx = Fx1+2 + Fx3+4
6-component summing processor in the charge amplifier can
Fy = Fy1+4 + Fy2+3 also perform the calculation in the same way. The distance from
the sensors must be included when calculating the moments.
Fz = Fz1 + Fz2 + Fz3 + Fz4
Mx = b ( Fz1 + Fz2 – Fz3 – Fz4 )

My = a ( –Fz1 + Fz2 + Fz3 – Fz4 )
Mz = b ( –Fx1+2 + Fx3+4 ) + a ( Fy1+4 – Fy2+3 )
www.kistler.com 9
Rotating dynamometers:
force and moment measurements
Mz
Application Fx
A rotating dynamometer can measure the three orthogonal
force components Fx, Fy and Fz — as well as the torque Mz — in
machining processes, including milling and drilling in particular. Fz
The 4-component force sensor is installed between the spindle
and the tool. The forces and moment are captured near the tool
Fy
edge, so the force vector acting on the tools can be determined
directly. Fx
Structure of a rotating dynamometer (RCD) Mz Fy

In the installed state, the measurement system’s rotor (with the Fz
force sensor) is connected to the machine spindle, so it rotates
along with the spindle. This means that the RCD’s coordinate
system also rotates around the vertical Z axis. Transmission of
digitized measurement signals to the stator, range switching
for the charge amplifier, and the power supply are all contact-
free. The stator is mounted on the machine tool at a distance of Fx
a few millimeters from the rotor. The RCD can be ordered with
Mz
various spindle adapters so that it can be used on many different Fy
machine types. Fz
RCD measuring chain

The measuring chain for a rotating dynamometer consists of
a rotating sensor, a stator for power and data transmission,
a signal conditioner for the signal output, and a data acquisition
box for signal recording.

Force signals from milling with a double-edged tool during finishing; left: forces in the x- and y-directions of the rotating dynamometer; right: resultant active force in the x-y plane
10 www.kistler.com
Benefits of a rotating dynamometer
•• The torque to be applied for cutting is measured directly.
This allows an accurate assessment of the tool condition
(regarding tool wear, for example)
•• The rotor in a rotating dynamometer rotates along with
the tool, so the mechanical load can be quantified directly
in the tool coordinate system
•• Because the measurement process is independent of the
mass, dimensions and form of the workpiece, forces and
moments can be measured in the cutting process for
complex and cost-intensive parts
Rotating dynamometer in use during machining of an impeller
RCD coordinate system

The RCD’s coordinate system rotates along with the tool. This
allows direct determination of the edge-related tangential and
normal cutting forces (Fc and FcN), for example during face
milling (see below). The cutting force can also be plotted in
a polar diagram.
Polar plot milling with a double-edged tool during finishing Polar plot milling with a four-edge tool, half-sectional view
www.kistler.com 11
Milling with a Type 9129AA stationary dynamometer
Cutting force measurement: milling

Stationary dynamometers
The stationary dynamometer is mounted on the machine tool
table and the workpiece is positioned on top of it. To reduce
the mass on the dynamometer and thus minimize the negative
influence on its dynamics, the workpiece is bolted directly onto
the dynamometer; this eliminates the need for heavy (and often
non-rigid) vises. In a few simple steps, the active force Fa acting
in the working plane can be calculated from the feed force and
the normal feed force.
12 www.kistler.com
Rotating dynamometers
A rotating dynamometer (RCD) is inserted directly into the
machine spindle, while the tool is connected to the RCD with

suitable tool holders. Because it is connected to the machine
spindle, the RCD rotates with it during operation. RCDs have
two advantages over stationary dynamometers: on the one

hand, the measuring instrument’s dynamics are not influenced
by changing masses, because the tool mass remains constant.
And on the other hand, the installed multi-component
sensor makes it possible to measure the moment Mz directly
throughout the entire measurement — so, for example, targeted
statements about tool wear become possible.

When RCDs are used, the active force Fa that acts on the

working plane can also be calculated from from forces Fx and Fy

in a few simple steps. The acting cutting force Fc and the normal
Typical measurement signals during milling (captured with a stationary cutting force FcN can be calculated with the help of the torque
dynamometer) Mz and the active force.
f Forces measurable with a stationary

dynamometer during milling
• Feed force Ff
Mz (force in the tool’s
direction of feed)
• Normal feed force FfN
(force perpendicular to Ff)
FfN Ff
• Passive force Fp
Fp Forces measurable with a rotating

dynamometer during milling
• Spindle moment Mz
• Passive force Fp
• Forces Fx and Fy in the
working plane
Forces and torque during face milling
www.kistler.com 13
Drilling with a Type 9170A rotating dynamometer
Cutting force measurement: drilling

Both stationary and rotating dynamometers (RCDs) can be used
to measure the process forces during drilling. An RCD is inserted
directly into the machine spindle, while the tool is connected to
the RCD with suitable tool holders. Because it is connected to
the machine spindle, the RCD rotates with it during operation.
The cutting force Fc and passive force Fp acting on the drilling

tool can be calculated with the help of the drilling moment
Mz and the deflective forces Fx, Fy; the feed force Ff can be
determined directly.
14 www.kistler.com
Rotating dynamometers are ideal for measuring forces during
drilling. They measure the drilling moment directly, and
accurately record the wear status of tools in the process.
Stationary dynamometers are also suitable for recording forces
during drilling. They measure the forces in three directions. In
this case, however, the torque is not measured directly but is
calculated using the various measurement signals from the force
sensors.

Components that can be measured

directly by a rotating dynamometer
during drilling processes
•• Drilling moment Mz
•• Deflective force Fx
•• Deflective force Fy
•• Feed force Ff
Components that can be measured

directly by a stationary dynamom-
Mz eter during drilling processes
•• Deflective force Fx
Fy •• Deflective force Fy
Fx
Ff
Forces and torque during drilling
www.kistler.com 15
Turning with a Type 9129AA dynamometer
Cutting force measurement: turning

Turning: a model machining process Stationary dynamometers for turning
Turning — and longitudinal turning in particular — is a model Stationary dynamometers are used to measure forces during
case for machining with a geometrically defined cutting edge; turning processes. These dynamometers have a partially modular
because the edge is constantly engaged in cutting, it is used to structure; they are usually mounted on the machine tool’s turret
determine and characterize specific forces (kc, kp, kf ) for certain head with the help of a suitable adapter. The tool is mounted
materials subject to different boundary conditions. Cutting on the dynamometer with a tool holder, so the dynamometer is
forces are often measured during the turning operation in order embedded between the tool and the turret head. This structure
to examine plastic-mechanical processes within the actual allows accurate and highly dynamic force measurements so that
cutting process, to analyze chip formation and its influence even the smallest changes in the process chain can be quantified
on the process, or to substantiate wear processes with force immediately.
progressions.
With the help of multi-component dynamometers, the main
cutting force generated by the turning process is broken down
directly into the three components: cutting force Fc, feed force Ff
and passive force Fp.
16 www.kistler.com
Typical measurement signals for turning Basic turning trials with a Type 9129AA dynamometer
Modular structure of stationary dynamometers f

Depending on the dimensions of the machine tool, tools and
loads, users can choose from several dynamometers to measure
cutting forces in turning operations. Thanks to their modular
design, they can be fitted with various machine adapters and
tool holders in just a few working steps. Because negative
thermal effects are minimized by the structural design of the
dynamometer, the signals are of considerably higher quality and
are much more informative.
Fp
Force components
Fc that can be measured
Ff directly during
turning
•• Cutting force Fc
•• Passive force Fp
Forces in longitudinal turning
www.kistler.com 17
Grinding with a Type 9129AA dynamometer
Cutting force measurement: grinding

Grinding is often the final machining operation performed in the
process of manufacturing a part. This means that it plays a very
important role in the quality of the finished part.
Strictly defined quality requirements such as roughness and
peripheral zone properties must be met, but it is also essential
to avoid production faults such as grinding burns and cracks.
To achieve these goals, it is important to understand the
relationships between process input and output parameters. The
measurement of the cutting force is an appropriate parameter
for determining cause-effect relationships and identifying
the reasons for undesirable results. Our extensive product
portfolio and the flexibility of our dynamometers allow force
measurements for a wide variety of grinding processes.
Typical measuring signal for grinding
Force components that can be measured directly during

grinding
•• Normal force Fn
•• Axial force Fa
•• Tangential force Ft
18 www.kistler.com
Cutting force measurement: micromachining
Micromachining sets extremely demanding requirements

for measuring technology in terms of sensitivity, and also as
regards the dynamics of the signals to be captured. The forces
that occur during micromachining range from 1 N to more
than 250 N. These must be mapped precisely and distinctly
in a process sequence. Another key criterion for recording the
process dynamics is the natural frequency of the measurement
equipment. If the frequency range containing the natural
frequencies of the force measurement equipment is too small,
the result will be over-excitation of the measurement setup.
There is then a risk that the amplitudes of the force signals
will tend to be overstated in the high frequency range. In the
worst case, the measurement setup will be excited at its natural
frequency, and the vibration of the setup will be greater than the
forces that actually occur in the process. This must be prevented
MicroDyn 9109AA on the machining table of a micromachining center at all costs.
Piezoelectric measurement technology is an excellent solution

to meet the requirements for micromachining. Thanks to the
use of highly sensitive, rugged crystals, one single measuring
instrument can be used to measure force signals in ranges from
well below 1 N to over 500 N. The advantages here are that
the measurement setup does not need to be changed between
tests, and reproducible measurements are guaranteed. Kistler
offers measuring instruments that are specifically designed for
use in micromachining. Thanks to their optimized rigidity and
mass, these dynamometers achieve exceptionally high natural
frequencies. In tests with double-edge tools at a spindle speed
of 160 000 rpm, for example, it has been proven that the
MicroDyn 9109AA can still reliably capture the force signals for
each individual engagement of the cutting edge.
Double-edge ball-nose milling cutter with diameter d= 0.2 mm for micromachining
Force signals recorded with a MicroDyn 9109AA The individual force curves for the engagements of both edges can be seen clearly — with engagement times of less than 1 ms
www.kistler.com 19
Cutting force measurement: application examples
Machining test for cylindrical grinding

The Institute of Machine Tools and Factory Management at
the Technical University of Berlin (TU Berlin) used a special
dynamometer to analyze grinding processes. This made
it possible to determine and improve part quality, wear
mechanisms and the critical material removal rate limit.
Using a special dynamometer to measure broaching forces

In this case too, the unique benefits of Kistler’s piezoelectric
technology were clearly proven. In the Laboratory for Machine
Tools and Production Engineering (WZL) at Aachen, a large
dynamometer was successfully used to measure and analyze
extremely small forces.
Kistler as your development partner

We view every application as an exciting challenge —
broaching, sawing, thread tapping, polishing and honing,
as well as classical applications such as milling, drilling,
turning and grinding. We shall be glad to act as your devel-
opment partner, working with you to devise individual
solutions for your measurement tasks. We can draw on
our lengthy experience as specialists in measuring a variety
of parameters including force, acceleration and acoustic
emissions. Our services range from advisory support
through to engineering of ready-to-install solutions.
20 www.kistler.com

Force signals during a turning process on materials that are difficult to machine; left: new tool; right: worn tool
Kistler also uses dynamometers to manufacture

its own products
Manufacturing thin-walled parts from materials that are difficult
to machine — such as membranes for pressure sensors — is an
operation that sets demanding requirements for the process
stability and surface quality of the parts. The process was
analyzed with the help of measurement technology from Kistler
— leading to significantly increased tool edge life and process
stability. The results: reduced production costs and a lower
scrap rate.
A high-precision flat honing machine with Kistler

dynamometers
In wafer fabrication, quality is determined by flatness, surface
roughness and the thickness of the disk. The material is usually
very hard and brittle. In the past, it was polished or honed
with the use of paste containing loose particles. Quality was
ensured, but the method was not efficient and contamination
levels were high. In Japan, Tohoku University collaborated with
the Matsushita Electronic Components Company to find a way
of making the process more efficient — thanks to technology
by Kistler. This special design was used to measure and analyze
the use of diamond-coated disks. And there were additional
benefits, too: handling was optimized and the error rate was
reduced.
www.kistler.com 21
Evaluation of cooling lubricants under operational conditions
Blaser Swisslube AG, located in Hasle-Rüegsau, is a leading
manufacturer of lubricants for metal machining. When it comes
to developing new cooling lubricants, this Swiss company puts
its trust in Kistler’s measurement expertise. Thanks to high-
precision measurement data, cooling lubricants are adapted
exactly to the application requirements during the practical
testing phase — so customers can rest assured that they will
function reliably later on.
Process optimization
Process optimization is the critical factor in boosting productivity
and enhancing the quality of machining processes — key factors
in ensuring that machining companies maintain their competitive
edge. For over ten years, MITIS has been developing systems for
vibration-assisted drilling. Systems of this sort are the solution
of choice in applications where chip breaking has a decisive
influence on the stability and efficiency of the process. Our Type
9255 cutting force systems are regularly deployed to optimize
the machining parameters and adjust the axial travel of the
vibration. As the result, cost-relevant process parameters can be
optimized without risking deformation of parts due to excessive
axial forces.
MITIS systems in operation: in this photograph, the workpiece is clamped onto

a Kistler 9255C dynamometer
Vorschubkraft (N)
Vorschubkraft (N)
1 000 1 000
500 500
0 0
11.06 11.26 11.46 13.02 13.22 13.42 13.62
Zeit (s) Zeit (s)
Fluctuation of axial force in vibration-assisted drilling. Force signals are used to optimize the parameters so that the tools are always engaged in cutting, chips break
reliably and the forces are minimized so as to prevent any part deformations
22 www.kistler.com
Products
MicroDyn: multi-component dynamometer with cover plate 30x30 mm, up to 500 N
Technical data Type 9109AA
S
Measurement range
D
Fz Fx, Fy, Fz (centrical) N –500 … 500
Fx Mz (single component) N .m –50 … 50
Calibrated measurement ranges
H Fx, Fy, Fz N 0 … 500
N 0 … 50
Fy N 0 … 10
Average sensitivity
Fx, Fy, pC/N ≈–12.5
Fz pC/N ≈–20
Natural frequency
(without additional mass)
fn(x) kHz >15
fn(y) kHz >15
fn(z) kHz >15
Operating temperature range °C –20 … 70
DxSxH mm 30x100x26
Weight kg 1.04
Degree of protection: IEC/EN 60529 IP67
(with connected cable)
Connector Fischer flange,
9-pole neg.
Data sheet: see www.kistler.com No. 9109AA_003-346
Key characteristics As a newly-developed addition to our range of stationary

dynamometers, this 4-component dynamometer can also
measure the moment Mz in the center of the dynamometer.
A very compact and rugged dynamometer with high sensi-
tivity and natural frequency. Ideal for measuring cutting
forces in micromachining.
Accessories
Steel baseplate for magnetic Art. No. 55174784
attachment
Mounting screws, M4x25 Art. No. 65012704
Accessories (optional)
Connecting cable for 6-comp. Type 1677A5 / 1677AQ02 /
force measurement 1679A5
www.kistler.com 23
MiniDyn: Multi-component dynamometer, up to 4 kN for table for turning

machining operations
Technical data Type 9119AA1 9119AA2 9119AA2 1)
W Fz L Measurement range
Fx
Fx, Fz kN –4 … 4 –4 … 4 –2 … 2 2)
H Fy kN –4 … 4 –4 … 4 –3 … 3 2)
Calibrated measurement
Fy ranges
Fx, Fz kN 0 … 4 000 0 … 4 000 0 … 2 000
kN 0 … 400 0 … 400 0 … 200
kN 0 … 40 0 … 40
Fy Fy kN 0 … 4 000 0 … 4 000 0 … 3 000
0 … 400 0 … 400 0 … 300
kN 0 … 40 0 … 40
Sensitivity
Fx, Fz pC/N ≈–26 ≈–26 ≈–26
Fy pC/N ≈–13 ≈–13 ≈–13
Natural frequency
Fz Fx fn(x) kHz ≈6.0 ≈4.3 ≈1.25 3)
fn(y) kHz ≈6.4 ≈4.6 ≈1.5 3)
fn(z) kHz ≈6.3 ≈4.4 ≈2.5 3)
Pretensioning direction horizontal horizontal
Operating temperature range °C –20 … 70 –20 … 70 –20 … 70
Clamping surface (area) mm 39x80x26 55x80x26 55x80

Weight g 930 1 350 depending on
adapter
Degree of protection: IEC/EN 60529 IP67 IP67 IP67
Connector Fischer flange, Fischer flange, Fischer flange,
9-pole neg. 9-pole neg. 9-pole neg.
Key characteristics The dynamometer with the smallest mounting dimensions. Thanks to
its optimized design and specially selected materials, this dynamometer
can attain natural frequencies of over 6 kHz in all three force directions
(Type 9119AA1). The highly sensitive crystals used in the dynamometer
enable it to achieve sensitivities three times greater than those of
conventional dynamometers. The benefit: even the very smallest forces
can be measured accurately. The horizontal pretensioning direction
guarantees that any influence of thermal effects on the measurement
signals is minimized.
1)
with adapters, Type 9119A...
2)
depending on the adapter
3)
applies to dynamometer Type 9119AA2 with machine adapter Type 9119AB30S and tool holder
Type 9119AE16, with tool (280 g)
24 www.kistler.com
Tool holders MiniDyn 9119AA2 Machine adapters
Turning tool, Type 9119AE... Accessories (optional): Straight shank (VDI), Type 9119AB...
Boring bar, Type 9119AF16 Connecting cable for 3-comp. force measurement Capto, Type 9119AC...
Type: 1687B5 / 1687BQ02 / 1688B5 / 1689B5 HSK-T, Type 9119AH63...
Connecting cable for 6-comp. force measurement
Type: 1677A5 / 1677AQ02 / 1678A5 / 1679A5
Data sheet: 9119AA1_003-060

9119AA2_003-055
Key characteristics
Modular measuring system based on the Type 9119AA2 dynamometer.
Machine adapters and tool holder nuts are easy to mount. We offer
a wide range of commonly used adapters to fit the Type 9119AA2
dynamometer.
Grinding with a Type 9119AA2 dynamometer
www.kistler.com 25
MidiDyn: multi-component dynamometer with 90x105 mm coverplate, up to 10 kN for table machining for turning operations
Technical data Type 9129AA 9129AA1)
W Measurement range
Fz L
Fx, Fz kN –10 ... 10 –5 … 5 2)
Fx
Fy kN –10 ... 10 –8 … 8 2)
H
Fy Fx, Fz kN 0 ... 10 0 ... 5
kN 0 ... 1 0 ... 0.5
kN 0 ... 0.1
Fy kN 0 ... 10 0 ... 8
kN 0 ... 1 0 ... 0.8
kN 0 ... 0.1
Fy Sensitivity
Fx, Fz pC/N ≈–8 ≈–8
Fy pC/N ≈–4.1 ≈–4.1
Fx Natural frequency
fn(x) kHz ≈3.5 ≈1.5 3)
Fz fn(y) kHz ≈4.5 ≈1.5 3)
fn(z) kHz ≈3.5 ≈2.5 3)
Pretensioning direction horizontal
Operating temperature range °C 0 ... 70 0 ... 70
LxWxH mm 90x105x32 90x105
Weight kg 3.2 depending on adapter
Degree of protection: IEC/EN 60529 (with IP67 IP67
connected cable)
Connector Fischer flange, Fischer flange,
9-pole neg. 9-pole neg.
Key characteristics Low overall height and a wide measuring range make this
dynamometer the ideal instrument for measurements
on high-precision machines. Its structure guarantees
high natural frequencies in all three force directions.
Negative influences due to temperature effects during
the measurement are significantly reduced thanks to the
horizontal pretensioning direction.
1)
with adapters, Type 9129A...
2)
depending on the adapter
3)
applies to dynamometer Type 9129AA with machine adapter Type 9129AB40 and tool holder
Type 9129AE25, with tool (280 g)
Milling with a Type 9129AA dynamometer
26 www.kistler.com
Tool holders MidiDyn 9129AA Machine adapters
Turning tool, Type 9129AE... Accessories (optional): Straight shank (VDI), Type 9129AB...
Boring bar, Type 9129AF40 Connecting cable for 3-comp. force measurement Clamping wedge, Type 9129AD...
Type: 1687B5 / 1687BQ02 / 1688B5 / 1689B5 Capto, Type 9129AC...
Connecting cable for 6-comp. force measurement CoroTurn SL, Type 9129AG40
Type: 1677A5 / 1677AQ02 / 1678A5 / 1679A5
Data sheet: 9129AA_000-709

9129AA_000-710
Key characteristics
Modular measuring system based on the Type 9129AA dynamometer,
featuring a wide measurement range. Machine adapters as well as tool
holders can be mounted on this dynamometer with minimum effort. We
offer a wide range of commonly used adapters to fit the Type 9129AA
dynamometer.
Turning with a Type 9129A dynamometer
www.kistler.com 27
MaxiDyn: multi-component dynamometer with 140x190 mm cover plate, up to 30 kN

Technical data Type 9139AA
Fz Measurement range (max. allowable)
W L
Fx, Fy, Fz kN –30 ... 30
Fx
Calibrated measurement ranges kN 0 ... 30
H
Fx, Fy, Fz kN 0 ... 3
Fy
kN 0 ... 0.3
Sensitivity
Fx, Fz pC/N ≈–8.2
Fy pC/N ≈–4.2
Natural frequency
fn(x) kHz ≈2.9
fn(y) kHz ≈2.9
fn(z) kHz ≈3.0
Pretensioning direction horizontal
Operating temperature range °C –20 ... 70
LxWxH mm 140x190x58
Weight kg ≈12.9
9-pole neg.
Data sheet: see www.kistler.com No. 9139AA_003-198

Key characteristics In this compact and robust dynamometer, the horizontal
pretensioning direction largely eliminates the negative
effects of temperature variations during measurement. Force
measurements in heavy-duty cutting processes are possible
thanks to the wide measurement range.
Type 1687B5 / 1687BQ02 / 1688B5 / 1689B5
Connecting cable for 3-comp. force
measurement
Connecting cable for 6-comp. force Type 1677A5 / 1677AQ02 / 1678A5 / 1679A5
measurement
Milling with a Type 9139AA dynamometer
28 www.kistler.com
Multi-component dynamometer with cover plate, 100x170 mm, up to 10 kN

Technical data Type 9257B
W Measurement range
Fz L
Fx, Fy kN –5 ... 5
Fx
Fz kN –5 ... 10
H
Fy Fx, Fy kN 0 ... 5
kN 0 ... 0.5
Fz kN 0 ... 10
kN 0 ... 1
Sensitivity
Fx, Fy pC/N ≈–7.5
Fz pC/N ≈–3.7
Natural frequency
fn(x), fn(y) kHz ≈2.3
fn(z) kHz ≈3.5
Pretensioning direction vertical
Operating temperature range °C 0 ... 70
LxWxH mm 170x100x60
Weight kg 7.3
9-pole neg.
Data sheet: see www.kistler.com No. 9257B_000-151

Key characteristics Dynamometer for universal use. Because of its handy dimensions
and ideal measurement range for many applications, the Type
9257B is manufactured in larger numbers than any other multi-
component dynamometer. It is connected to the machine table
via lateral flanges with oblong holes.
Type 1687B5 / 1687BQ02 / 1688B5 / 1689B5
Connecting cable for 3-comp. force
measurement
measurement
Tool holder Type 9403
Waterproof protective cap for Type 1431A1
cable connection
Screw tapping with a Type 9257B dynamometer
www.kistler.com 29
Multi-component dynamometer with cover plate, 260x260 mm, up to 60 kN

Technical data Type 9255C
W Fz L Measurement range
Fx Fx, Fy kN –30 ... 30
Fz kN –10 ... 60
H Calibrated measuring ranges
Fy
Fx, Fy kN 0 ...30
kN 0 ... 3
Fz kN 0 ... 60
kN 0 ... 6
Sensitivity
Fz pC/N ≈–3.9
Natural frequency
fn(x) kHz ≈2.2
fn(y) kHz ≈2.2
fn(z) kHz ≈3.3
LxWxH mm 260x260x95
Weight kg 52
9-pole neg.
Data sheet: see www.kistler.com No. 9255C_003-051

Key characteristics Rugged dynamometer for heavy-duty machining, with the
largest force range of all our dynamometers. It is connected to
the machine tool table via lateral flanges with oblong holes.
The dynamometer can also be fixed through the center of the
four sensors, which increases its natural frequency.
Connecting cable for 3-comp. force Type 1687B5 / 1687BQ02 / 1688B5 / 1689B5
measurement
measurement
cable connection
Milling with a Type 9255C dynamometer
30 www.kistler.com
Multi-component force plate with cover plate, 400x600 mm, up to 30 kN

Technical data Type 9253B22 9253B23
W Measurement range
Fz L
Fx, Fy kN –15 ... 15 –12 ... 12
Fx
Fz kN –15 ... 30 –12 ... 25
H
Fy Fx, Fy kN 0 ...15 0 ... 12
Type 9253B22 1) kN 0 ... 1.5 0 ... 1.2

Fz kN 0 ... 30 0 ... 25
kN 0 ... 3 0 ... 2.5
Sensitivity
W Fz L Fx, Fy pC/N ≈±7.8 ≈±7.8
Fx
Fz pC/N ≈±3.7 ≈±3.7
H
Natural frequency
Fy fn(x) Hz ≈580 ≈610
fn(y) Hz ≈550 ≈570
Type 9253B23 2) fn(z) Hz ≈720 ≈570
Pretensioning direction vertical vertical
Operating temperature range °C –20 ... 70 –20 ... 70
LxWxH mm 600x400x100 600x400x100
1)
Weight kg 90 85
cover plate with tapped hole, M10x18
2)
cover plate with T-grooves, 10H12 Degree of protection: IEC/EN 60529 IP67 IP67
Connector Fischer flange, Fischer flange,
9-pole neg. 9-pole neg.
Data sheet: see www.kistler.com No. 9253B_000-146 9253B_000-146

Key characteristics The cover plate measuring 400x600 mm also ensures safe
mounting of larger workpieces. The force plate is mounted
on the machine tool table through the center of the four
feet. In this case, the base plate is not used (in contrast to all
other stationary dynamometers).
measurement
measurement
cable connection
www.kistler.com 31
4-component dynamometer to measure cutting forces during drilling
Technical data Type 9272
D
Measurement range
d Fx, Fy kN –5 ... 5
Fz
Fz kN –5 ... 20
Mz Mz N·m –200 ... 200
Fx Calibrated measurement ranges
Fx, Fy kN 0 ... 5
Fy kN 0 ... 0.5
H Fz kN 0 ... 20
kN 0 ... 2
Mz N·m 0 ... ±200
N·m 0 ... ±20
Sensitivity
Fz pC/N ≈–3.5
Mz pC/N·m ≈–160
Natural frequency
fn(x), fn(y) kHz ≈3.1
fn(z) kHz ≈6.3
fn (Mz) kHz ≈4.2
DxdxH mm ø100xø15x70
Weight kg 4.2
9-pole neg.
Data sheet: see www.kistler.com No. 9272_000-153

Key characteristics This 4-component dynamometer is the only stationary model
that allows direct measurement of the moment Mz in the
center of the dynamometer, in addition to the three force
directions. This allows precise determination of the torque.
measurement
Tool holder Type 9404
Waterproof protective cap for cable Type 1431A1
connection
Force measurement during quartz cutting with a Type 9272 dynamometer
32 www.kistler.com
Multi-component quartz force link kit, up to 60 kN
Technical data Type 9366CC...
Fz
Measurement range
Fx, Fy kN –25 ... 25 1)
Fx
Fz kN –25 ... 60 1)
H
Fy
Fx, Fy kN 0 ... 25
D kN 0 ... 2.5
Fz kN 0 ... 60
kN 0 ... 6
Sensitivity
Fz pC/N ≈–3.8
Natural frequency
fn(x), fn(y), fn(z) Hz ≈200 ... 1 600 1)
DxH mm 72x90
Max. size of the cover plate mm 900x900
Weight kg 7
Degree of protection: IEC/EN 60529 (with IP67
connected cable)
1)
depending on cover plate size and material
9-pole neg.
Data sheet: see www.kistler.com No. 9366CC_000-681

Key characteristics Users can assemble their own multi-component force plates
with this ready-to-connect pre-calibrated multi-component
kit. Cover plate sizes from 300x300 mm to 900x900 mm are
possible.
measurement
measurement
cable connection
Machining titanium with a Type 9366CC dynamometer
www.kistler.com 33
Rotating 4-component dynamometer (RCD) to measure cutting forces up to 20 000 rpm

Technical data Type 9170A...
Measurement range (nominal)
Fx, Fy kN –5 ... 5 1)
Fz kN –20 ... 20 1)
Fy Mz N·m –150 ... 150 1)
Speed, max. 1/min 20 000 1)
H Sensitivity (min./max.)
Fx, Fy mV/N ≈2/≈20
Fz mV/N ≈0.5/≈5
Fx Mz mV/N·m ≈66/≈1 000
D
Mz Natural frequency
fn(x) kHz ≈2 2)
Fz
fn(y) kHz ≈2 2)
fn(z) kHz ≈7.6 2)
DxH mm 85x95
Weight of rotor kg 1.6 2)
Degree of protection: IEC/EN 60529 (with IP67
connected cable)
Signal transmission contact-free
Data sheet: see www.kistler.com No. 9170A_000-995
Key characteristics This rotating 4-component dynamometer (RCD) measures
the forces in the radial direction (Fx, Fy) and the axial
direction (Fz) and also the torque in cutting processes
with spindle speeds of up to 20 000 rpm. Internal cooling
lubricant supply is possible. Measurement signal trans-
mission and energy supply are contact-free, so wear is
entirely eliminated. We offer a wide variety of commonly
used spindle adapters for this RCD.
1) depending on spindle adapter and force applica-

tion point
2) applies to rotor with spindle adapter HSK-A63

and integrated ER collet chuck adapter (without
tool)
1
2 3
4
Signal Conditonier
Type 5238B
Dynamometer Analog Output Remote Control
Power Sync. Error Measure

1 ... 10mm Signal
Operate
Conditioner
Dynamometer Remote
Output Filter
Fx Range Fx, Fy Range Fz Range Mz Rotor 9170 Rotor 9171
1 1 1 3kHz 1kHz
2 2 2 1kHz 300Hz
Mz
Fy
3 3 3 300Hz 100Hz
Fz RS-232C Remote Control Test

Fy
Fz
Fx
/Measure
Mz Trigger
Fz
Fy EGND
Mz GND DGND
Fx +24V
Fz 1 Rotor, Type 9170A...

Mz
2 Stator, Type 5236B
Fy
Fx
3 Cable, Type 1500A95, L = 10 m
4 Signal conditioner, Type 5238B1/B2
34 www.kistler.com
Rotor
Spindle adapters HSK-A40, HSK-A50,
HSK-A63, HSK-A80,
HSK-E50, HSK-E63
DIN 69871-AD30, DIN
69871-AD40, DIN
69871-AD50
MAS 403 BT 30, MAS 403
BT 40, MAS 403 BT 50
CAT 30, CAT 40, CAT 50
Capto C5, Capto C6
Key characteristics Spindle and tool adapters are permanently installed in

the RCD 9170A. It is no longer possible to exchange the
adapters after installation.
Milling an impeller with a Type 9170A rotating dynamometer
www.kistler.com 35
Rotating 4-component dynamometer to measure cutting forces in heavy-duty machining, up to 12 000 rpm
Fy Measurement range (nominal)
Fx, Fy kN –20 ... 20 3)
H Fz kN –30 ... 30 3)
Mz N·m –1 000 ... 1 000 3)
Speed, max. 1/min 12 000
D
Fx Sensitivity (min./max.)
Mz
Fx, Fy mV/N ≈0.5/≈4.8
Fz Fz mV/N ≈0.3/≈4.8
Mz mV/N·m ≈9/≈96
Natural frequency
fn(x) kHz ≈1.1 1)
fn(y) kHz ≈1.1 1)
fn(z) kHz ≈7.6 1)
DxH mm 118x85
Weight kg 3.3 2)
Signal transmission contact-free
Key characteristics Thanks to its wide measurement range and speeds of up

to 12 000 rpm, this rotating 4-component dynamometer
is especially suitable for heavy-duty cutting applications.
The rotor’s modular design makes it easy to exchange
different spindle and tool adapters at any time. Internal
cooling lubricant supply is possible. Measurement signal
transmission and energy supply are contact-free, so wear is
entirely eliminated.
1) applies to rotor with spindle adapter HSK-A100,

without tool adapter
2) applies to rotor without spindle adapter

and without tool adapter
3) m
easurement range depends on spindle adapter 1
type. See the data sheet
2
3
Signal Conditonier
Type 5238B
Dynamometer Analog Output Remote Control
Power Sync. Error Measure

Signal
Operate
Conditioner
Dynamometer Remote
Output Filter
Fx Range Fx, Fy Range Fz Range Mz Rotor 9170 Rotor 9171
1 1 1 3kHz 1kHz
2 2 2 1kHz 300Hz
Mz
Fy
3 3 3 300Hz 100Hz
Fz RS-232C Remote Control Test

Fy
Fz
Fx
/Measure
Mz Trigger
Fz
Fy EGND
Mz GND DGND
Fx +24V
1 Rotor, Type 9171A...

Fz
Mz
2 Stator, Type 5236B
Fy 3 Cable, Type 1500A95, L = 10 m
Fx 4 Signal conditioner, Type 5238B1/B2
36 www.kistler.com
Rotor
Technical data Type 9171A
Spindle adapters HSK-A63, HSK-A80,
HSK-A100
DIN 69871-AD40,
DIN 69871-AD50
MAS 403 BT 40,
MAS 403 BT 50
CAT 40, CAT 50
Capto C6, Capto C8
Tool adapters • Collet chuck, type

PowRgrip PG32-SG by
Rego Fix
• Collet chuck, type ER32
(DIN 6499-B32)
• Collet chuck, type ER40
(DIN 6499-B40)
• Collet chuck, MEGA
New Baby Chuck by BIG
KAISER
• TENDO hydraulic
expansion toolholder by
Schunk
Key characteristics Spindle adapters and tool adapters are built into the RCD
9171A on a modular basis, or they can be obtained singly.
Adapters can be changed at any time. (Important: The rotor
must be balanced after every changeover.)
BIG KAISER Schunk Rego Fix

MEGA New Baby Chuck TENDO SecuRgrip
www.kistler.com 37
Amplification, acquisition and evaluation
— all from one single source
Measurement Amplification and acquisition
Rotating dynamometers Signal conditioners
Stationary dynamometers Charge amplifiers
The dynamometer is the centerpiece of every measurement

setup. It captures the physical variable to be measured, and Kistler offers standalone data acquisition systems as well as
transmits it to the charge amplifier in the form of a charge systems with an integrated charge amplifier. For stationary
signal. Two types of dynamometer are used: stationary dynamometers, the LabAmp 5167A charge amplifier can be
dynamometers are usually mounted on the machine table, used directly; it converts the charge signal into a voltage and
whereas rotating dynamometers are inserted into the spindle via performs an analog-to-digital conversion. Users can then view
the spindle interface, and they rotate with the spindle. the data in the DynoWare software.
38 www.kistler.com
Evaluation
Data acquisition system
DynoWare
LabAmp
DynoWare is all-purpose, easy-to-use software that is partic-

The integrated data acquisition principle can only be used ularly suitable for force measurements with dynamometers and
for measurements with stationary dynamometers. Rotating single-component or multi-component force sensors. For signal
dynamometers also require a signal conditioner to supply the analysis, DynoWare users benefit from online visualization of
rotor and transmit the data. Our Type 5697 data acquisition measurement curves as well as helpful calculation and graphics
system is used for rotating dynamometers, and for high- functions.
precision measurements with the Type 5080 charge amplifier.
This system is also compatible with DynoWare to analyze and
visualize the data.
www.kistler.com 39
The LabAmp family
The LabAmp family comprises Types 5167A and 5165A:

together, they can amplify and record large numbers of signals
from different sensor types. Charge amplifier 5165A is suitable
for dynamic measurements of voltages, IEPE (Integrated
Electronics Piezo-Electric) and charge signals. As opposed to
LabAmp 5165A, the LabAmp 5167A system is designed for static
force measurements.
Physical variables
•• Force
•• Acceleration
•• Pressure
•• Voltage
High-precision measurement and acquisition of forces in cutting processes

Together with the stationary dynamometers, the LabAmp 5167A charge amplifier forms a complete measuring
chain to capture forces and moments in cutting processes. This charge amplifier’s high-insulation inputs ensure
measurements with minimal drift. Its low-noise design also makes it possible to measure small force signals. The
4- or 8-channel version can be used according to the dynamometer and application area.
To record additional force, acceleration, pressure or voltage signals, the LabAmp 5167A can be combined with
further 5165A/5167A devices. This makes the LabAmp family an integral solution for cutting process analyses.
40 www.kistler.com
Data visualization in DynoWare
DynoWare (or other software provided by
the user) handles further data processing
and visualization. DynoWare features
a variety of functions designed specif-
ically for analyzing force signals in cutting
processes. Examples include temperature
drift compensation and numerous filter
options. LabAmp 5167A communicates
with the PC via Ethernet and is configured
either with DynoWare or in a browser.
Software and configuration

•• DynoWare
•• Web browser
•• LabVIEW interface
Multi Device Client

The Precision Time Protocol (PTP) feature enables networking with additional LabAmp devices (such as the
5165A/5167A) via Ethernet. The measurement signals of the different devices are given synchronized time
stamps for this purpose.
Remote control
The LabAmp 5167A has separate digital inputs for automated measurements so that measurements can be
remote-controlled. Measurements can also be triggered by signal rises on individual channels.
www.kistler.com 41
Measuring chains
Measurement Connection Amplification and acquisition
9119AA1 1687B5 (3 components) LabAmp 5167A81 Ethernet cable

3 or 8 measuring components
9119AA2 1689B5 (3 components) LabAmp 5167A41

9129AA 1677A5 (8 components)
9253B...
9255C
9257B
9366CC...
9272 1677A5 LabAmp 5167A81 Ethernet cable

4 measuring components
1679A5 LabAmp 5167A41
9119AA1 1687B5 (3 components) 5080A... 1700A111A2

9119AA2 1689B5 (3 components) 1200A27
9129AA
Messen 1677A5 (8 components)
Verbinden Verstärken
3, 4 or 8 components,

9253B...
9255C
high-precision
9257B
Stationäre Dynamometer
9366CC...
Rotating dynamometers (RCD)

9170A... 5236B 1500A95 5238B... 1700A111A2
9171A... 1200A27
42 www.kistler.com
Analysis
Notebook
with DynoWare software
Notebook
5697A... USB cable Notebook

Erfassen Analysieren
5697A... USB cable Notebook

www.kistler.com 43
Charge amplifiers
High-end multi-channel charge amplifier for multi-component force measurements

Number of channels 1 ... 8
Measurement range FS pC ±2 ... 2 200 000
Measurement range adjustment continuously variable
Frequency range (–3 dB) kHz 0 ... 200
Output signal V ±10 / –8 ... 10
Modules, optional – charge amplifier
– Dual Mode
(charge/Piezotron)
Power supply
VAC 100 ... 240
VDC 11 ... 36
Input signal Type/ Piezoelectric,
connector according to choice
with:
– BNC neg.
– Fischer 9-pole neg.
Output signal Type/ – BNC neg.
connector – D-Sub 15-pole neg.
Interface – RS-232C
– USB 2.0
Case, optional – 19" rack module
(DIN 41494)
– Desktop unit with
support bracket
Other features Display of mechanical
variable
Key characteristics This charge amplifier has outstanding properties that make
very precise measurements possible, particularly when small
forces are involved. Thanks to its highly flexible structural
design, it can be modified in line with requirements at any
time. As well as pure charge amplifier modules, we also offer
dual-mode modules that allow connection of sensors with
a charge output as well as sensors with integrated electronics
(Piezotron).
RS-232C cable Type 1200A27
Connecting cable Type 1700A111A2
Inductive proximity switch Type 2233B
44 www.kistler.com
Data acquisition system with integrated charge amplifier
Charge amplifier and data acquisition system for multi-component force measurement
Number of channels
Type 5167A41 4
Type 5167A81 8
Input connector Fischer 9-pole neg.
Output connector BNC neg.
Ethernet interface 2xRJ45
Remote control D-Sub 9f
Measurement range pC ±100 … 1 000 000
Frequency range (–3 dB) Hz ≈0 … >45 000
Nominal output voltage V ±10
Output impedance Ω 10
ADC resolution Bits 24
ADC sampling rate kSps 625
Output rate per channel (configurable) kSps 100
Filter type Bessel or Butterworth

Order 2./4.
Data sheet: see www.kistler.com No. 5167Ax1_003-278
Key characteristics This data acquisition system includes integrated charge

amplifiers and is suitable for multi-component force
measurements. Control is via Ethernet. The system can also
be configured with DynoWare to visualize the data. An ideal
choice for measurements with stationary dynamometers in
cutting processes.
Accessories
Ethernet cable
Dynamic multi-channel charge amplifier and data acquisition system

Number of channels 4
Input connector BNC neg.
Output connector BNC neg.
Measurement range pC ±100 … 1 000 000
Nominal output voltage V ±10
ADC resolution Bits 24
ADC sampling rate kSps 625
Output rate per channel (configurable) kSps 100
Filter type Bessel or Butterworth

Order 2./4.
Kistler’s Type 5165A LabAmp charge amplifier is the
Key characteristics universal laboratory amplifier for dynamic signals.
Piezoelectric sensors, Piezotron sensors (IEPE) and voltage
signals are all digitized and processed with high resolution.
Simple data acquisition functions as well as freely confi-
gurable analog outputs highlight the extensive range of
applications for this device.
www.kistler.com 45
Data acquisition system
DAQ system for data acquisition from up to 28 measuring channels

Number of measuring channels 28
Resolution Bits 16
Sampling rate, max.
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, fem.
Dimensions mm 208x70x249
Weight kg 2.2
Key characteristics This universal-use data acquisition system samples analog

signals up to 1 MHz. When combined with our DynoWare
software, it can be used to control all Kistler laboratory
charge amplifiers and signal conditioners. The connection
with the PC is via a USB interface. DynoWare software is
available in the package together with the data acquisition
system.
RS-232C cable Type 1200A27
Inductive proximity switch Type 2233B
Software
DynoWare: Windows data acquisition software

Supported charge amplifiers Types 5011, 5015A...,
5018A..., 5017, 5019,
5070A..., 5080A...
Supported signal conditioners for Types 5223B..., 5237A...
rotating dynamometers (RCD) 5238B...
For further information, see the data sheet
Supported operating systems Windows 7
Windows 8
Windows 10
Accessories
Data acquisition system Type 5697A...
46 www.kistler.com
DynoWare
This simple-to-operate software enables users to configure and A number of evaluation functions are available to analyze
control all laboratory charge amplifiers, LabAmp devices, and the data acquired:
signal conditioners via RS-232C, USB or Ethernet (IEEE-488).
It also offers simultaneous recording of measurement signals •• virtual channels can be created for manipulated signals
as well as helpful signal evaluation and calculation functions. •• data manipulation using calculation functions
Export of the the measurement data acquired is simple. •• digital filtering
The software can record and evaluate any desired physical •• Fast Fourier Transform (FFT) on full or partial ranges
measurands (including quasistatic force signals in particular). In •• signals can be displayed as polar coordinates
addition to the sensor configuration, it is possible to configure •• drift compensation
the sampling rate, hardware filter, and remote control for data •• triggers
acquisition.
FFT function Polar plot

The FFT function in the DynoWare software displays a signal in Polar plot is a DynoWare function for evaluating measurements
the frequency spectrum. With the cursor, the user can select the by rotating dynamometers. This special graphic plots the
range of the force signal for which the FFT should be displayed. moment on the tool in the rotating tool coordinate system,
This allows analysis of the smallest details in the process. allowing edge-based analysis of the cutting forces.
www.kistler.com 47
Connecting cables, high-insulation
Cable, 8-core/3-core, temperature range –5 ... 70°C

Technical data Type 1677A5 1687B5
Connector Fischer 9-pole pos., Fischer 9-pole pos.,
flange flange
Fischer 9-pole pos. Fischer 9-pole pos.

Length m 5 5
Diameter mm 12.3 (metal sheath) 12.3 (metal sheath)
Number of conductors 8 3
Used for 6-component 3-component
measurements measurements
Cable with angle connector, 8-core/3-core, temperature range: –5 ... 70°C

Technical data Type 1679A5 1689B5
Connector Fischer angle Fischer angle
connector, connector,
9-pole pos., flange 9-pole pos., flange
Length m 5 5
Diameter mm 12.3 (metal sheath) 12.3 (metal sheath)
Cable, 8-core with flexible metal-mesh jacket, temperature range: –5 ... 70°C
Technical data Type 1677AQ02 1687BQ02
Connector Fischer 9-pole pos., Fischer 9-pole pos.,
flange flange

Length m 5 5
Diameter mm 10.5 (metal 10.5 (metal
mesh jacket) mesh jacket)
48 www.kistler.com
Accessories
Cable for transmission of measurement signals

Technical data Type 1700A111A2
Connector D-Sub 15-pole neg.
D-Sub 15-pole pos.
Length m 2
Number of conductors 15
Cable for transmission of measurement signals

Technical data Type 1700A113A2
Connector D-Sub 15-pole neg.
BNC pos.
Length m 2
Cable for transmission of communication signals

Technical data Type 1200A27
Connector D-Sub 9-pole pos.
D-Sub 9-pole neg.
Length m 5
Waterproof protective cap for cable connection

Technical data Type 1431A1
Connector Fischer 9-pole pos.
Additional sensors for frequency analyses
Technical data Type 9722A500 9722A2000

Range N 0 ... 500 0 ... 2 000
Overload N 2 500 10 000
Sensitivity, nom. mV/N 10 2
Resonant frequency kHz 27 27
Technical data Type 8202A10 8203A50

Range g ±2 000 ±1 000
Threshold (noise 100μVrms) gms 0.001 0.001
Sensitivity, nom. pC/g –10 –50
Resonant frequency, installed, nom. kHz 45 24
Our full range of accelerometers is presented in catalog 900-380e.
Capto is a registered trade mark of the Sandvik Group

PowRgrip and SecuRgrip are registered trade marks of Rego-Fix AG
MEGA New Baby Chuck is a registered trade mark of BIG DAISHOWA Group
TENDO is a registered trade mark of the Schunk Group
Windows is a registered trade mark of Microsoft Corporation
www.kistler.com 49
Kistler service: customized solutions from A to Z
For over 50 years, Kistler has been setting standards in cutting As well as our extensive range of measurement solutions
force measurement. As your experienced partner, we’re there to for cutting forces, Kistler also offers sensors and systems for
help you with our extensive technical expertise and our applica- general test and measurement applications. Learn more at:
tion-specific know-how. www.kistler.com/de/de/anwendungen/sensor-technology/test-
measurement.
Kistler’s team of engineers is on hand to assist you with every
step of the process — from planning, commissioning and
on-site system training through to routine maintenance and Our services at a glance
repairs. Drawing on our lengthy experience and thanks to close • Custom engineering
cooperation with our customers, we can supply custom solutions • Advisory support
that meet the specific requirements of your application. To learn • Commissioning support
more about our solutions for cutting force measurement, visit: • Periodic calibration
www.kistler.com/de/de/anwendungen/sensor-technology/ • Training courses/workshops
zerspankraftmessung.
50 www.kistler.com
Headquarters,
Detroit Sindelfingen Winterthur Shanghai Yokohama
Sales center
Tech center
Production center
At our customers’ service across the globe

Thanks to Kistler’s global sales and service network, we are
always close to our customers. Approximately 2 000 employees
at 61 locations are dedicated to the development of new
measurement solutions and offer customized on-site support
of individual applications.
www.kistler.com 51
©2019 Kistler Group
960-002e-04.19
Flexible to create
Take the lead – Safe braking and easy
right from the start thanks to efficient
to integrate
maintenance
Now d!
certifie
OIML- )
(R134
Biomechanics Brake force measurement in Weigh In Motion

Force measurement solutions for motion analysis,
sports performance diagnostics, rehabilitation and ergonomics
the rail transport sector Measuring equipment for a wide variety of traffic data
collection, enforcement and toll collection applications
Sensors and accessories for periodic brake force testing
www.kistler.com www.kistler.com www.kistler.com
Measuring Develop and Analyzing and

equipment for operate gas commanding
demanding T&M turbines more sophisticated
applications efficiently machining
processes
Test & Measurement Gas turbine monitoring Cutting force measurement

Sensors and signal conditioning overview
Measuring combustion dynamics improves turbomachinery Precise measuring systems for machining
performance
Find out more about our applications:

www.kistler.com/applications
www.kistler.com
www.kistler.com www.kistler.com
www.kistler.com
Kistler Group
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. +41 52 224 11 11
Kistler Group products are protected by various intellectual

property rights. For more details, visit www.kistler.com.
The Kistler Group includes Kistler Holding AG and all its
subsidiaries in Europe, Asia, the Americas and Australia.
Find your local contact at

www.kistler.com
52 www.kistler.com

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Analyzing and

Kistler develops measurement solutions

Fundamentals of cutting force measurement 4

Force and moment measurement 8

Cutting force measurement 12

Amplification, acquisition and evaluation

The LabAmp family 40

Kistler service: customized solutions from A to Z 50

At our customers’ service across the globe 51

Fundamentals of cutting force measurement

Regardless of batch size, the manufactured products are

Benefits of force measurement technology by Kistler

Stationary dynamometers Rotating dynamometers

Rotating system for measurements

Rotating system for large forces and

The expert solution for

Table-mounted system for precision

The expert solution for precision

Best-seller and all-rounder for table

Compact solution for somewhat larger

The classic model for table mounting

Robust platform, optimized for

Solution for large workpieces with

The expert solution for drilling trials

Pre-loaded, ready calibrated set

suitable limited suitability

Structure of a stationary dynamometer

Stationary dynamometer measuring chain

Benefits of a stationary dynamometer

3-component force measurement 6-component force and moment measurement

Mx = b ( Fz1 + Fz2 – Fz3 – Fz4 )

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

Structure of a rotating dynamometer (RCD) Mz Fy

RCD measuring chain

Rotating dynamometer in use during machining of an impeller

RCD coordinate system

Cutting force measurement: milling

f Forces measurable with a stationary

Fp Forces measurable with a rotating

Cutting force measurement: drilling

The cutting force Fc and passive force Fp acting on the drilling

Components that can be measured

Components that can be measured

Forces and torque during drilling

Cutting force measurement: turning

Modular structure of stationary dynamometers f

Cutting force measurement: grinding

Typical measuring signal for grinding

Force components that can be measured directly during

Micromachining sets extremely demanding requirements

Piezoelectric measurement technology is an excellent solution

Machining test for cylindrical grinding

Using a special dynamometer to measure broaching forces

Kistler as your development partner

Kistler also uses dynamometers to manufacture

A high-precision flat honing machine with Kistler

MITIS systems in operation: in this photograph, the workpiece is clamped onto

Data sheet: see www.kistler.com No. 9109AA_003-346

Key characteristics As a newly-developed addition to our range of stationary

MiniDyn: Multi-component dynamometer, up to 4 kN for table for turning

1) depending on spindle adapter and force applica-

2) applies to rotor with spindle adapter HSK-A63

1) applies to rotor with spindle adapter HSK-A100,

2) applies to rotor without spindle adapter