Objectives:

To determine the effect of the following parameters on the tool forces, that is
in the orthogonal metal cutting; tool feed rate, cutting speed and depth of cut.
Also, to calculate the specific cutting pressure and power consumed at the
cutting edge.


Equipments:

1. lathe machine
2. Cutting tool
3. Material for cooling the work piece and the cutting tool and it consist of
water and oils.

Theory:

1- Cutting speed (V): its the relative surface speed between the tool
and the job. Its given as:

min) / (
1000
m
DN
V


Where:
D: Diameter in mm of work piece
N: rev/min of work piece
V: cutting speed of work piece in m/min

2- Feed: its small movement per cycle of the cutting tool, relative to the
work piece in such direction. It's expressed in (mm/rev).


3- Depth of cut: its the thickness of the layer of metal removed in one
cut, or pass, measured in a direction perpendicular to the machined
surface. the depth of cut (W) is given as:

) (
2
2 1
mm
D D
W



Where:
2 , 1
D D Is the initial and final diameter of the work piece

4- Total force :

F = F
c
+ F
f
+ F
r


F
c
: cutting force , it is the largest force , it act in the direction of cutting
velocity .
Feed force , it is in the direction of the tool feed , 50 % of F
c
: F
f
F
t
: thrust force , it is perpendicular to the machined surface.


Procedure:
1. put the work piece and make sure that every thing is set .
2. turn on the machine and set the depth of cut that you need.
3. turn on the automatically cut and it will cut the work piece.
4. we can read the forces ( radial ( thrust ) , feed , cutting ) from the display that is
on the top of the cart that have the cutting tool .















Analysis:

Result (1): constant cutting speed (v) and feed rate(f), with a variable
depth of cut (w).
D=21.00 mm N=950rpm f=0.200 mm/rev

Radial force (f
r
)
(N)
Axial force (f
f
)
(N)
Tangential force (f
c
)
(N)
Depth of cut (w)
mm
10 19 39 0.5
17 39 72 1
37 71 126 1.5
41 78 150 2.0




When the depth of cut increase; then the tangential force increase, and the
Axial and radial force also increase. And it is clear that F
c
has the greatest
magnitude, because it is the largest force that need the most amount of power
to do the cutting process.




0
20
40
60
80
100
120
140
160
0 0.5 1 1.5 2 2.5
f
o
r
c
e
s

N

depth of cut mm
Relation between the cutting forces and the
depth of cut
Tangential force (fc) (N)
Axial force (ff) (N)
Radial force (ft) (N)
Result (2): constant feed rate (f) and depth of cut (w), with a variable
constant speed (v)
D=20.60mm w=0.5mm f=0.25 mm/rev

Radial force (f
r
)
(N)
Axial force (f
f
)
(N)
Tangential force
(f
c
) (N)
cutting speed
(V)
N (rev/min)
29 55 124 46 710
38 57 118 55 850
36 54 110 75 1160
29 51 108 82.2 1270






increasing the cutting speed will lead to increasing in cutting forces, when the
cutting velocity increase, then the tool life reduced, and it is clear that the short life
of the cutting tool happens because the cutting forces is larger with the higher speed,
and when the speed is increase, this means that it is wanted to remove a larger
amount of metal in less time, so the cutting force have to be larger




0
20
40
60
80
100
120
140
0 20 40 60 80 100
f
o
r
c
e
s

N

cutting speed m/min
Relation between the cutting forces and the
cutting speed
Tangential force (fc) (N)
Axial force (ff) (N)
Radial force (fr) (N)
Result (3): constant cutting speed (v) and depth of cut(w), with a variable
feed rate (f).
D=20.60 mm N= 1150 rpm w=0.25mm

Radial force (f
r
)
(N)
Axial force (f
f
)
(N)
Tangential force (f
c
)
(N)
feed (f) (mm/rev)
20 36 66 0.200
26 55 94 0.315
45 85 118 0.400
40 78 130 0.500


When the feed increase, this means that the amount of metal removed is larger, and
to remove a larger amount of metal; a larger force is needed, so, increasing the feed
rate will lead to an increase in the cutting forces.







0.5, 130
0.5, 78
0.5, 40
0
20
40
60
80
100
120
140
0 0.1 0.2 0.3 0.4 0.5 0.6
f
o
r
c
e
s


N

feed rate mm/rev
Relation between the cutting forces and the
feed rate
Tangential force (fc) (N)
Axial force (ff) (N)
Radial force (fr) (N)
Sample calculation:
Part(1)
Specific cutting pressure (S.C.P) =

Power consumed (P) =

Part (2)
Specific cutting pressure (S.C.P) =

Power consumed (P) =

Part (3)
Specific cutting pressure (S.C.P) =

Power consumed (P) =

Conclusion:
We conclude from this experiment that the cutting speed ( v ) increase by
increasing ( N ) or ( D ) and when we increase the cutting speed and the
revolution ( N ) it will cause increase in the energy that is coming from the
cutting tool .
We conclude that the specific cutting pressure was maximum at the lowest
depth of cut and feed rate.
We conclude that the Power was maximum at the highest cutting speed.