Cutting Force Measurement

Objectives:
To measure the following components of forces acting on a cutting tool during turning
operation:
o Feed force component
o Thrust force component
o Cutting force component
To correlate the changes in the cutting force components with changes in cutting speed,
feed rate and depth of cut.

Major Equipments/Tools Used:

Lathe Machine, Kistler Piezoelectric dynamometer mounted on tool post, Cylindrical
Aluminium work piece, Carbide tool, Kistler software, Vernier Caliper

Theory:
During turning, three mutually perpendicular forces act on the cutting tool. The dynamometer
used to measure forces operates on piezoelectric technology. Following are the forces,

Cutting force (FZ): This force acts along the direction tangential to cutting edge at the
point of contact with work piece.
Radial Force (FY): This acts along the radius of the workpiece at the point of contact.
This force prevents tool separation during cutting operation.
Feed Force (FX): This is the force acting along the direction of feed.

There are two types of cutting, orthogonal and oblique. In this experiment we are performing
orthogonal cutting. The machining parameters are:

Cutting Velocity: It is the relative velocity between the cutting tool and workpiece.
Feed Rate: It is the rate of approach of the cutting tool towards un machined surface.
Radial Depth of Cut: It is the depth from the surface of the workpiece to which the
cutting tool cuts.

Procedure
The workpiece was mounted on the lathe and centrered.
The diameter of workpiece was measured using a digital Vernier caliper.
 Readings for the cutting forces were then taken from the software for all possible
combinations of the cutting parameters shown below.

Speed(rpm) Feed(mm/rev) Depth of Cut(mm)

147 0.04 0.5
190 0.06 1
247 0.08 1.5

Observations:
Workpiece diameter = 33.9mm

Cutting Tool used: TNMG160412CQ

Fz =Mean cutting force

Fx = Mean feed force

Fy = Mean radial thrust force

1. Feed= 0.04 mm/ rev, depth of cut= 0.5 mm

Speed(rpm) Fz (N) Fx (N) Fy (N)

147 219.8 93.32 118.2

190 215.7 109.4 93.77

247 202.7 83.01 135.8

2. Feed=0.06 mm/rev, depth of cut=0.5 mm

Speed(rpm) Fz (N) Fx (N) Fy (N)

147 327.5 105.6 197

190 320.5 106.3 254.3

247 300.2 78.37 243.7

 3. Feed=0.08 mm/ rev, depth of cut=0.5 mm

Speed(rpm) Fz (N) Fx (N) Fy (N)

147 469.3 101.7 375.8

190 462.4 107.8 223.7

247 452 158.3 434.4

4. Feed=0.04 mm/rev, depth of cut=1 mm

Speed(rpm) Fz (N) Fx (N) Fy (N)

147 503.40 334.1 284.9

190 424.5 316.8 400.2

247 368.6 170.2 279.3

5. Feed=0.06 mm/rev, depth of cut= 1 mm

Speed(rpm) Fz (N) Fx (N) Fy (N)

147 671.4 243.1 409.4

190 660.6 315.4 511.1

247 650.5 493.5 521.2

6. Feed=0.08 mm/rev, depth of cut= 1 mm

Speed(rpm) Fz (N) Fx (N) Fy (N)

147 792.3 331.3 601.3

190 776.5 465.5 662.0

 247 768.1 456.8 690.4

7. Feed= 0.04 mm/ rev, depth of cut= 1.5 mm

Speed(rpm) Fz (N) Fx (N) Fy (N)

147 938.8 837.9 551

190 918.6 808.3 495.4

247 752.9 712.6 341.8

8. Feed = 0.06 mm/rev, depth of cut= 1.5 mm

Speed(rpm) Fz (N) Fx (N) Fy (N)

147 1183 866.5 716.6

190 1016 637.5 756.1

247 952.1 561.9 752.7

9. Feed= 0.08 mm, depth of cut= 1.5 mm

Speed(rpm) Fz (N) Fx (N) Fy (N)

147 1235 879 831.3

190 1168 792.1 782.8

247 1059 689.4 760.6

Discussion:
The measurement of cutting force components is useful for:

Calculating the power of the machine tool required for a given operation.
 In designing the tool and choosing the tool material.
In estimating the tool life and tool wear.

Conclusion:
The following inferences can be drawn from the observations,

1. Cutting force components increase with feed, force and radial depth of cut.
2. Cutting force components decrease with speed.
3. Changes in the depth of cut affect the cutting forces more significantly as compared to
feed rate and speed.