Cutting Force Measurement

Mohak Patel 9003045

Aim To study the influence of the turning process parameters (RPM, feed, Depth of cut) on cutting force. Procedure The method used by us was turning of a cylindrical object on the traditional Lathe machine. The steps involved were as follows: 1. 2. 3. 4. 5. Firstly, mount the mild steel cylinder on the chuck. As the dynamometer is already fixed to the tool, set the tool for turning process. Set the lathe for desired RPM and feed rate also set the depth of cut required. Record the force components as measured by the dynamometer. Repeat the above steps 3 and 4 for different combinations of RPM, Feed Rate & depth of cut. 6. Now change the material from mild steel to Aluminum. 7. Repeat the above experiment for this also and record the data. 8. Using the various forces calculate the power consumption and hence comment on the result obtained. Background The component of force acting in the direction of cutting is known as Cutting Force (F c). Figure 1 shows the different forced that acts on cylindrical surface. The instrument used to measure the components of force is known as Dynamometer. The tool force is measured using the strain developed in the strain gauges or in some cases piezoelectric loads are also used for increased resolution and stiffness. The forces measured using this are very helpful in calculation many variables in the process of chip formation. The force helps us in optimizing the cutting parameter also we can analyse the cutting process.

Figure 1: Forces on cutting tool

Three principal forces during a turning process: The cutting or tangential force acts downward on the tool tip. It supplies the energy required for the cutting operation. The axial, thrust or feed force acts in the longitudinal direction. This force tends to push the tool away from the chuck. The radial force acts in the radial direction and tends to push the tool away from the workpiece.

The power consumed by the machine largely depends on the cutting force and is given as below: Pc = Fc V Where; Fc is cutting force & v is the cutting speed. Feed power is calculated as: Pf= Ff Vf Where; Ff feed force & Vf is feed velocity. Also, the power consumed by radial force component is very less and is hence always neglected and considered zero. Observation and Calculation Formulae Used: m/s; m/s;

1. For Aluminum
RPM Depth of cut, t (mm) 0.25 0.75 0.25 0.75 0.25 0.75 0.25 0.75 Fc (N) Ff (N) Fr (N) Feed rate, (MM/rev.) 0.175 0.175 0.175 0.175 0.350 0.350 0.350 0.350 Radius (mm) Vf (m/s) 2.63 10-4 2.63 10 4.08 10 8.17 10 8.17 10 5.25 10 5.25 10
-4 -4

Vc (m/s) 8.48 10-2 8.01 10 12.1 10 11.0 10 10.3 10 6.36 10 5.89 10

-2 -2

Pf (J/s) 3.413 10-3 3.938 10 3.267 10 1.633 10 2.450 10 0.525 10 1.575 10

-3 -3

Pc (J/s)

90.0 90.0 140 140 140 140 90.0 90.0

20.0 23.0 16.0 13.0 6.00 8.00 4.00 10.0

13.0 15.0 8.00 5.00 2.00 3.00 1.00 3.00

7.00 6.00 5.00 2.00 0.00 1.00 0.00 3.00

9.00 8.50 8.25 7.75 7.50 7.00 6.75 6.25

1.70 1.84 1.93 1.48 0.659 0.821 0.254 0.589

4.08 10-4
-4 -4 -4 -4

11.4 10-2
-2 -2 -2 -2

2.042 10-3
-3 -3 -3 -3

2. For Mild Steel

RPM

90.0 90.0 140 140 90.0 90.0 140 140

Depth of cut, t (mm) 0.25 0.75 0.25 0.75 0.25 0.75 0.25 0.75

Fc (N)

Ff (N)

Fr (N)

Feed rate, (MM/rev.) 0.350 0.350 0.350 0.350 0.175 0.175 0.175 0.175

Radius (mm)

Vf (m/s) 5.25 10-4 5.25 10 8.17 10 8.17 10 2.63 10 2.63 10 4.08 10 4.08 10
-4 -4 -4 -4 -4 -4 -4

Vc (m/s) 11.5 10-2 11.1 10 16.8 10 16.1 10 10.1 10 9.70 10 14.6 10 13.9 10
-2 -2 -2 -2 -2 -2 -2

Pf (J/s) 1.57 10-3 4.20 10 4.08 10 5.72 10 1.56 10 2.63 10 2.45 10 4.08 10
-3 -3 -3 -3 -3 -3 -3

Pc (J/s)

12.0 22.0 12.0 19.0 18.0 28.0 19.0 29.0

3.00 8.00 5.00 7.00 6.00 10.0 6.00 10.0

2.00 5.00 3.00 6.00 4.00 6.00 6.00 8.00

12.25 11.75 11.50 11.00 10.75 10.25 10.00 9.50

1.38 2.44 2.02 3.06 1.82 2.70 2.78 4.04

Result and analysis 1. Machining of steel consumes much more power than that of aluminium. Hence, more power is needed for machining harder metal 2. The power consumed is directly proportional to RPM. The other two components are also directly proportional to the power. Sources of error 1. The dynamometer was highly sensitive and its reading varied a lot. 2. Error involved in giving depth of cut. 3. Variation in force measurement due to the vibrations. Conclusion The power consumed is directly proportional to all the three parameters feed, rotational speed and depth of cut. Also all the three parameters affect the dimensional accuracy of the final product.