PROJECT TILTLE

FORCE ANALYSIS ON ALUMINUM ROD:

FIFTH SEMESTER
GROUP MEMBERS
ROHAIL ALI (G.L) CU-424-2016
MUHAMMAD TOUSEEQ CU-392-2016
MUAZAM JAMIL CU-370-2016
HAMAYUM KHALIL CU-751-2016

ADVISER
Engr Dr RIAZ Muhammad

SUBMITTED TO:
ENGR ASIM AHMAD RIAZ

MECHANICAL ENGINEERING DEPARTMENT

CECOS UNIVERSITY OF I.T & EMERGING SCIENCES
HAYATABAD PESHAWAR, PAKISTAN
Approval sheet
The author have passed their project report requirements.
Abstract:
This endeavor illustrates the analysis of forces on aluminum rod and to find these forces
by using sensor mean (dynamometer) which produced the thrust force and torque. These forces
are very important for drilling operation in Engineering. Based on the analysis of forces on
aluminum rod and to find these forces by using sensor mean the thrust force and the sensor also
give torque to solve the problems of the of daily life by being using the new idea.

Aluminum alloy is taken because it is easily available, lighten in weight and drill easily,
take less time and non-corrosive material. Therefore in this thesis aluminum rod is taken and cut
in to the small work pieces using power hack saw in over required dimension. Then install the
software in the laptop (met lab and dynamometer) and then connect to the milling machine then
tightly clamp the drill bit in the milling machine chuck then we select feed rate and rpm in the
milling machine then we tightly clamp the work piece in the dynamometer vice then start the
milling machine when the tool touch the work piece we start the dynamometer reading by click
start and when the drill occur we stop the dynamometer and save the reading and then we change
the work piece and repeat the procedure for further work pieces. Construct different graphs
between forces with time and torque with time and we observe that when we increase the feed
rate the thrust force will be high while we decease the feed rate the thrust force will required less.

keywords
Thrust force, Aluminium, drilling, dynamometer, Torque, Matlab, Milling Machine,
Time, Hack saw
Acknowledgment:
First, we are very thankful to almighty Allah for his blessing on us. It
gives in-depth pleasure to express our immense sense of gratitude and regards for our respected
advisor DR.RIAZ MUHAMMAD, DEPARTMENT OF MECHANICAL ENGINEERING,
CECOS UNIVERSITY PESHAWAR. Who has always enlightened us with his thoughtful
ideas during the course of our entire project? Without his worthy input, we would not be able to
accomplish his project.

In addition, we are thankful to the faculty of mechanical engineering for their support.
Dedication:
This project is dedicated to our parents by the prayers of whom we have withstood
when the circumstances demanded and our dedicated, supportive and encouraging teaching staff
without the support of whom we would not be able to stand where we are now.
Table of contents:
Title page…………………………………………………………………………………..i

Abstract…………………………………………………………………………………….ii

Acknowledgement………………………………………………………….……………...iii

Dedication…………………………………………………………………………………..iv

1. Introduction ……………………………………………………………………………
2. Methodology or experimental setup…………………………………………………..
3. Specimen………………………………………………………………………………..
4. Result and discussion ………………………………………………………………….
5. Conclusion ……………………………………………………………………………..
6. References………………………………………………………………………………

List of tables and list of figures

Figure ………………………………………………………………………(1)
Figure ………………………………………………………………………(2)
Figure ………………………………………………………………………(3)
Figure ………………………………………………………………………(4)
Figure ………………………………………………………………………(5)
Table …………………………………………………………………………(a)
Table …………………………………………………………………………(b)
Table …………………………………………………………………………(c)
Table …………………………………………………………………………(d)
Table …………………………………………………………………………(e)
1)Introduction:
Aluminum is a metal that is found abundantly and consist of 8%of the earth’s crust. It is found in
different alloyed forms like silicon, lead, zinc, manganese, copper etc. Aluminum material are
non-corrosive easily available and many people used it in all over the world.

Aluminum has very important physical properties such as strength of aluminum. Its pure
state it not too much strength but addition of alloy (silicon, paganize, copper) make it strengthen.
Density of aluminum is approximately one third of the copper or steel, corrosion resistance a
layer form in the aluminum which prevent the aluminum for the corrosion, electrical
conductivity aluminum have high conductivity, thermal conductivity of the aluminum is three
times greater than steel and aluminum also a best heating and cooling application etc.

Aluminum has also good mechanical properties some of them is deformation aluminum can
have deformed by rolling extruding, drawing, machining mean they deformed several times
without failure casting aluminum can be cast, cold working and heat treating operation also will
be done by their properties. Tensile strength pure aluminum have 90 MPa they increase by
addition alloy to 690 MPa, ductile aluminum have ductile properties etc.

Aluminum have a lot of applications in all over the word, fever of them is aircraft aluminum
has important application in aircraft mostly the aircraft body are made, automobile fuel filter are
made by aluminum. Ship parts are made by aluminum , mobile circuits are made by aluminum.
Home windows are made in aluminum, kitchen instruments make in aluminum, Nuclear industry
used aluminum for the cap closing and also a pharmaceutical industry used aluminum for the
caps etc.

Some previous work done on aluminum is as follow:

Emanuele Cannella et al work on Ejection force analysis of sintered aluminum micro gears
using a shrink-fit die principle [1]. Such work can be seen in [2] where Failure Mode Analysis
of Aluminum Alloy 2024-T3 in Double-Lap Bolted Joints with Single and Double Fasteners
using A Numerical and Experimental Study by Khosro Fallahnezhad. Similar work can be seen
in [3] by P. Ravinder Reddy where Analysis of Orthogonal Cutting of Aluminium-based
Composites has studied.

Morten F et all applied prediction of cutting force in metal cutting using the finite elements method,
a lagrangian approach [4]. In [5], A.petek studied ,Deformations and forces analysis of single
point incremental sheet metal forming. In [6] Abdel-Hakim Bouzid work on Failure Analysis of
an Aluminum Extension Portable Ladder. [7] deals with work done by Baruku Kasuga et all in
which Inhibition of Aluminium Corrosion Using Carica papaya Leaves Extract in Sulphuric Acid.
In [8] Débora G. Santarossa et all work on the Green Photolumine scent Methodology for
Aluminium Traces Quantification in 24-Hour Urine of Subjects with Different Exposition to
Tobacco Smoke. In [9] S. Basavarajappa et al work on Analysis of burr formation during drilling
of hybrid metal matrix composites using design of experiments. In [10] P.S. Sivasakthivel et al
studied deep on Cutting force prediction depending on process parameters by response surface
methodology in milling.
Many people in the word used drilling machine but they do not know which forces are applied to
over work piece in drilling operation because of lack of sensor in the drilling machine. So we used
dynamometer sensor to measures these forces. These forces are given below:

Force analysis is the analysis of the force which occurs when the work piece get in touch with
the cutting tool. When the connection is made two kind of forces are generated i.e., cutting force
(the force required to cut a unwanted material of the work piece. These forces are perpendicular to
thrust force) and thrust force (is the pushing force which provided by the spindle during the contact.
Thrust force is along the spindle axis).
``

2)Methodology or Experimental setup

I. Machine model
 Victoria.

II. SPECIFICATIONS:
 Table vertical movement: 15inches
 Table horizontal cross movement: 6.5inches
 Table horizontal longitudinal movement: 22inches
 Motor: 10hp, 3PH, 420v.
 Power supply: 3PH, 50hz, 420v.

III. Material
We take Aluminum material because it is soft, non corrosive and drill easily.

IV. Sensor
We used Dynamometer to get the forces reading.

V. Tool
In our project we used HSS drill bit it is strength and low cost.

VI. Procedure
1. Cut the aluminum rod in small work pieces using power hacksaw.
2. Then filing operation on the upper and the bottom surfaces of the work pieces.

Step 1: Select a drill bit that matches the size of the hole that need to drill into the aluminum.
Step 2: Attach the drill bit tool and properly locked it into place .

Step 3: Laid the aluminum rod down on a flat work surface. Because it is circular in shape and
need to secure the metal to the bench with clamps to keep it from rolling around.

Step 4: Used a permanent marker to indicate the spot where need to drill a hole. This will help to
improve the accuracy when attempting to drill through the metal.

Step 5: Connect the dynamometer to the laptop and tightly clamp the dynamometer vice in the
milling machine.

Step 6: Tightly clam the 10mm drill bit in the chuck of milling machine.

Step 7: Give feed rate and rpm and automatic mode and cross feed automatically up.

Step 8: When the drill bit tool touch the surface of work piece the start the MATLAB and when
drilling complete stop the MATLAB software and save the reading.

Step 9: Draw graphs according to the obtained results with help of excel.

Figure 1
VII. Flowchart:

3)Specimen:
The diameter of the specimen is 23 mm and length is 20mm.
 0
500
0
500

-500
1000
1500
2000
1000
1500
2000
1 1

Sample 1
4)Results
52 48
103 95
154 142
205 189
256 236

Feed 0.53 and rpm 43

307 283
358 330
409 377

Load(N)

-1000
0
1000
2000
460 424

Torque(N-m)
511 1 471
562 52 518
613 103 565
664 154 612
715 205 659
766 256 706
307
358
409

Load(N)
0
1000
1500
2000

-500
500
460

-2000
-1000
0
1000
2000
511 1
1 49
562
29 97
613
57 145
664
85 193
715
113 241
766
141 289
169 337
197 385
225 433
Load(N)

253 481
281

Torque(N-m)
529
309 577
337 625
365 673
393 721
421 769
449
 0
500
1000
1500
2000

-500

2000
4000
6000

-2000
1 1

Sample 2
9 11
17 21
31
25
41
33

Feed 3.4 and 77 rpm

51
41
61
49
71

load (N)
57

0
500
1000
1500
2000
81
65
1 91
0
1000
1500
2000

500

73

Torque(N-m)
9 101
81 111 1
17
89 45
25 121
97 89
33
133
105 41
177
113 49
221
121 57
265
65

Load(N)
309

0
500
1000
1500
2000

-500
73
1 353
81
397

1000
2000
3000
4000
5000
6000

0
89 12
441
Torque(N-m)

1 97 23
34 485
12 105 529
23 113 45
34 573
121 56
45 617
67
56 661
78
67 705
89
Load (N)

78 100
89
111

Torque(N-m)
100
122
111
122 133
133 144
144 155
155
 Torque(N-m)
6000
5000
4000
3000
2000
1000
0

85

120
1
8
15
22
29
36
43
50
57
64
71
78

92
99
106
113
Sample 3
Feed 2.6 and 141 rpm

Load(N) Load(N)
2000 2000

1500 1500

1000 1000

500 500

0 0
51
1
11
21
31
41

61
71
81
91
101
111
121
131
141

1 7 13 19 25 31 37 43 49 55 61 67 73 79 85 91

Load (N)
2000
1500
1000
500
0
109
1
13
25
37
49
61
73
85
97

121
133
145
157
169
 0
200
400
600
800
0
500
1000
1500
2000
1
1
15

Sample 4
15
29
29
43
43
57
57
71
71
85
85 Feed 1.35 and 308 rpm
99
99
113
113
127
Load(N)
127
141

Torque(N-m)
141
155
155

0
1000
1500
2000

-500
500
169
183 169
1
197 183
24
211 197
47
225 211
70
225
93
116
139

0
200
400
600
800
162

Load (N)
1 185
0
500
1000
1500
2000

22 208
1
43 231
254 18
64
277 35
85
300 52
106
69
127
86
148
103
169
120
Load(N)

190
137

Torque(N-m)
211
154
232
171
253
188
274
205
295
222
316
 0
0

200
400
600
800
500

1000
1200
1400
1800
1000
1500
2000

1600
1 1

Sample 5
20 23
39 45
58 67
77 89
96 111
115 133

Feed 0.57 and 548 rpm

134 155
153 177

Load(N)
172 199
191 221

Load(N)
243
0
200
400
600
800

210
229 265 1
248 287 23
267 309 45
286 331 67
305 89
111
133

0
500
1000
1500
2000
155
1
177
17
199
Torque(N-m)

33 221
49 243
65 265
81 287
97 309
113
129
145
Load(N)

161
177
193
209
225
241
 0
0

200
400
600
800
200
400
600
800

1000
1200
1400
1000
1200
1400
1 1
18 23
35 45
52 67
69 89
86 111
103 133
120 155
177
137
199
Torque(N-m)

154
221

Torque(N-m)
171
243
188
265
205 287
222 309
239 331
256
273
 0
200
400
600
800
1000
1200
1400
1
23
45
67
89
111
133
155
177
199
Torque(N-m)

221
243
265
287
309
331
353
Sample 6
Feed 6.2 and 1010 rpm

Load(N)
2000

1500

1000

500

0
1 4 7 101316192225283134374043464952555861

Load(N)
2000

1500

1000

500

0
1

100
10
19
28
37
46
55
64
73
82
91

109
118
127
136
145
154
163

Torque(N-m)
1600
1400
1200
1000
800
600
400
200
0
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61
 Torque(N-m)
2000

1500

1000

500

0
1
11
21
31
41
51
61
71
81
91
101
111
121
131
141
151
161
Torque(N-m)
2000

1500

1000

500

0
1 4 7 10131619222528313437404346495255

Load(N)
1800
1600
1400
1200
1000
800
600
400
200
0
1 5 9 13 17 21 25 29 33 37 41 45 49 53
5) Conclusion:
• We came to the conclusion that we get the forces generating high when the feed rate
increased, and the force generated low when the speed is increased which means that the
feed rate is directly related to forces and inversely proportional to the speed.
• At the end, we got another conclusion that from testing we can calculate unknown forces
by selecting different speed and different depth of cuts.
References:
1. Cannella, E., Nielsen, E. K., & Arentoft, M. (2016). Ejection force analysis of sintered
aluminium micro gears using a shrink-fit die principle. In Proceedings of the 11th
International Conference on Multi-Material Micro Manufacture (4M2016) : co-organised
with 10th International Workshop on Microfactories (IWMF2016) (pp. 41- 44). 4M
Association. DOI: 10.3850/978-981-11-0749-8 694.

2. Khosro Fallahnezhad, Andrew Steele and Reza H. Oskouei *, Failure Mode Analysis of
Aluminium Alloy 2024-T3 in Double-Lap Bolted Joints with Single and Double Fasteners;
A Numerical and Experimental Study, Materials 2015, 8, 3195-3209;
doi:10.3390/ma8063195.

3. P. Ravinder Reddy and A.A. Sriramakrishna,; Analysis of Orthogonal Cutting of

Aluminium-based Composites, Defence Science Journal, Vol. 52, No. 4, October 2002, pp.
375-38.
4. Morten F et all preduction of cutting force in metal cutting ,using the finite elements method
,a lagrangian approach,7LS-DYNA Anwenderform,Bamberg 2008
5. A.petek ,Deformations and forces analysis of single point incremental sheet metal
forming.vol.35,No 2,Feburary 2009,pp.107-116.
6. Abdel-Hakim Bouzid, Failure Analysis of an Aluminum Extension Portable Ladder,
Vol.5 No.9(2014), Article ID:48449,11 pages DOI:10.4236/msa.2014.59069
7. Baruku Kasuga , Inhibition of Aluminium Corrosion Using Carica papaya Leaves Extract in
Sulphuric Acid, Vol.06 No.01(2018), Article ID:81269,14 pages 10.4236/jmmce.2018.61001
8. Débora G. Santarossa, Green Photoluminescent Methodology for Aluminium Traces
Quantification in 24-Hour Urine of Subjects with Different Exposition to Tobacco Smoke,
Vol.09 No.10(2018), Article ID:88005,15 pages 10.4236/ajac.2018.910038
9. S. Basavarajappa Analysis of burr formation during drilling of hybrid metal matrix
composites using design of experiments, International Journal of Machining and
Machinability of Materials (IJMMM), Vol. 1, No. 4, 2006
10. P.S. Sivasakthivel, Cutting force prediction depending on process parameters by response
Surface methodology in milling, International Journal of Machining and Machinability of
Materials (IJMMM) Vol. 11, No. 2, 2012