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CUTTING FORCE MEASUREMENT
Manufacturing Technology Lab I III Semester A & B
AIM :
To measure the cutting forces for the given cutting conditions.
TOOLS AND EQUIPMENTS REQUIRED :
Lathe, Lathe Tool Dynamometer.
PROCEDURE :
1. The Lathe Tool Dynamometer is initially set to zero reading.
2. The known depth of cut is given and take the readings of P x and Pz force
components from the Lathe Tool Dynamometer.
3. Calculate the resultant cutting force
P = Sqrt (Px2 + Pz2)
4. Repeat the same procedure to get few more readings and calculate the
mean cutting force.
5. Repeat the same procedure for different depth of cuts.
RESULT :
Thus the cutting forces are measured for different depth of cuts.
Px
Py
Px
Py
Pz
Pz
TABULATION :
DEPTH
HORIZONTAL
VERTICAL
RESULTANT
AVERAGE
SL.
OF CUT COMPONENT COMPONENT P = Sqrt (Px2 + Pz2)
NO.
(mm)
Px (kg)
Pz (kg)
(Kg)
(Kg)
1
0.50
2
0.50
3
0.50
4
0.50
1
2
3
4
0.75
0.75
0.75
0.75
NOTE :
1. Pz the main or tangential component, determines the torque on main
drive mechanism, the deflection of the tool and the required power. This
component acts in the direction of the cutting speed.
2. Px the axial component, acts in the direction of the tool traverse and it
is at right angles to Pz. It contributes very little to the power
consumption.
3. Py the radial component, acts along the tool shank and perpendicular
to the other two components. It has no share in the power consumption.
EXERCISE NO. 2
SHEAR ANGLE MEASUREMENT
AIM :
To measure the shear angle to the given conditions.
TOOLS AND EQUIPMENTS REQUIRED :
Lathe, Single point turning tool, Micrometer.
PROCEDURE :
1.
2.
3.
The chip is taken for thickness inspection. Find the mean chip thickness, t2.
4.
5.
Calculate the shear angle for the given rake angle of the tool.
rc cos
tan = ----------1 - rc sin
where, - rake angle.
6. Repeat the same procedure to get few more readings and calculate the
mean shear angle.
7. Repeat the experiment for different depth of cuts.
t2
t1
Tool
Workpiece
NOTE :
1. The value of Shear angle depends on the cutting conditions, tool geometry,
tool material and work material.
2. If the Shear angle is small, the plane of the shear is large, the chip is
thicker, more force is required to remove the chip.
3. If the shear angle is large, the plane of shear will be shorter and the chip is
thin. Hence, less force is required to remove the chip.
CHIP THICKNESS :
LC = Least Count
DEPTH PITCH SCALE HEAD SCALE HEAD SCALE
CHIP
SL. OF CUT
READING
COINCIDENCE
READING
THICKNESS
NO.
t1 (mm)
(PSR)
(HSC)
HSR = HSC*LC t2 = PSR + HSR
1
0.25
2
0.25
3
0.25
4
0.25
1
2
3
4
0.50
0.50
0.50
0.50
SHEAR ANGLE :
UNCUT
CHIP
CHIP
SHEAR ANGLE
CHIP
THICKNESS THICKNESS
AVERAGE
SL.
RATIO
SHEAR ANGLE
NO. THICKNESS
1
2
3
4
t1 (mm)
0.25
0.25
0.25
0.25
1
2
3
4
0.50
0.50
0.50
0.50
t2 (mm)
r c = t1 / t2
RESULT :
Thus the shear angle is found for different depth of cuts.
EXERCISE NO. 3
SURFACE GRINDING
AIM :
70
50
50
To grind the workpiece to the given tolerance using surface grinding machine.
70
90.01
10
50
18
=(Z+2)m
= 2.25 m
= 1.5708 m
where,
Z = Number of teeth required
m = module
2. Indexing calculation
Index crank movement = 40 / Z
3. The dividing head and the tail stock are bolted on the machine table. Their
axis must be set parallel to the machine table.
4. The gear blank is held between the dividing head and tailstock using a
mandrel. The mandrel is connected with the spindle of dividing head by a
carrier and catch plate.
5. The cutter is mounted on the arbor. The cutter is centred accurately with
the gear blank.
Then the gear blank is indexed for the next tooth space.
13.
CALCULATION :
Z = No. of teeth
= 23
m = module
= 2 mm
Blank Diameter
= (Z + 2) m
= (23 + 2) 2
= 50 mm
Tooth Depth
= 2.25 m
= 2.25 * 2
= 4.5 mm
Indexing Calculation
= 40 / Z
= 40 / 23
= 1 17/23
RESULT :
Thus the required gear is machined using the milling machine to the required
number of teeth.
EXERCISE NO. 5
CAPSTAN LATHE
AIM :
12
18
20
12
18
EXERCISE NO. 6
ASSEMBLY - I
AIM :
To machine and assemble the given workpieces to the given dimensions using
required machines.
18
30
M 25.4 x 3.75
40
10
30
Chamfer 45 x 2
EXERCISE NO. 7
ASSEMBLY - II
AIM :
20
10 5
5 10
50
55
40
40
50
55
To machine and assemble the given workpieces to the given dimensions using
required machines.
20
S=20
Thus the required hexagonal surface is machined using the milling machine to
the given dimensions.
CALCULATION :
Diameter, D = 2 x S
Distance across the Flat
Depth of cut
(1.5 x S) + 3mm
INDEXING CALCULATION :
For Hexagonal surface, the number of faces, Z = 6.
Simple Indexing
40
---Z
40
---6
26
6 ---39
EXERCISE NO. 9
CNC LATHE
AIM :
20
20
10
30
20
20