BENG (HONS) MECHANICAL/ELECTRONICS & ELECTRICAL

ENGINEERING

IN COLLABORATION WITH THE UNIVERSITY OF SUNDERLAND

MANUFACTURING PROCESS
EAT227

Workshop Topic: MACHINING PROCESSES

Submitted by: Ho Kim Xiang

UOS ID: SCSJ-0018699

Date:

EVALUATION:

INTRODUCTION & OBJECTIVES 10 marks

THEORY 15 marks
PROCEDURES 15 marks
RESULTS 15 marks
DISCUSSION 15 marks
CONCLUSION 15 marks
REPORT PRESENTATION 15 marks
OVERALL MARK 100 Marks

Name and signature (of evaluator): .

MACHINING Operations - Turning and drilling
Introduction & Objective
1
 To machine a closed die for powder metallurgy part.
To produce a high accuracy workpiece.
To complete the workpiece in the most simplest and effective way.

Material

Mild Steel cylindrical rod 25 mm diameter & 100 mm long.

Mild Steel cylindrical rod 25 mm diameter & 53 mm long.

Tools Required

Steel Rule, Marking knife, Vernier callipers, Chuck Key, Cutting tool, Drilling tool, Lathe machine.

Operations Required

1. Job setting 2. Facing

3. Plane turning 4. Marking

5. Stepping 6. Edge cutting

7. Resetting 8. Finishing

9. Drilling 10. Inspection

Theory

1. Orthogonal cutting
The cutting edge is straight.
It is set in a position that is perpendicular to the direction of primary motion.
This allows us to deal with stresses and strains that act in a plane.

2
 Cutting forces :

Total cutting force F is conveniently

resolved into horizontal component FC and
vertical component FD.
Cutting force FC is in the direction of
primary motion. The cutting force formed
about 70~80 % of the total force F and is
used to calculate the power P required to
perform the machining operation, P =

Fc x V .
Thrust force FD is in direction of feed
motion in orthogonal cutting. The thrust
force is used to calculate the power of feed
motion.
Fc x V
The cutting horsepower = Hp c =
33000

2. Oblique cuttiing
The cutting edge is set at an angle (the tool cutting edge inclination s).
This is the case of three-dimensional stress and strain conditions.

3
 Cutting Force :

Extra one force component appears along the third

axis.
Thrust force FD is further resolved into two more
components,
Feed force Ff is the direction of feed motion.
Back force Fp is the other perpendicular to it and
to the cutting force FC , which is in the direction
of the cutting tool axis.
Fc > Ff > Fp (100% > 40-50% > 25%)
Cutting force = Fc + Ff + Fp
2 2 2

Fc
Cutting force per unit area = k c = Ac
Fc x V c
Power of machine = PC = 60

V
Rotational speed = N = Do
Feed rate = Fr = N x f

4
 L
Time of machining = T m = fr
Material Removal Rate = MRR = vfd

3. Cutting Temperature
Nearly total energy consumed in machining converted into heat.
High temperature will reduce tools life and cause dimension error in the machined surface.
Heat generated is shared by the chip, cutting tool, and the blank.
10-20 % of the total heat goes into the tool and some heat is absorbed in the blank.

Primary heat source

Major part of energy is
converted into heat.
Secondary heat source
Further heat is
generated at the chip due
to shear.
Heat loss Friction
between the chip and
tool on the tool flank.

3 Modes of Tools Failure

Fracture failure Brittle fracture will occur, when the cutting force is exceeded the tool point.

5
 Temperature failure - This failure occurs when the cutting temperature is too high for the tool
material, causing the material at the tool point to soften, which leads to plastic deformation and
loss of the sharp edge.

Gradual failure - Gradual wearing of the cutting edge causes loss of tool shape, reduction in
cutting efficiency, accelerated wear, and final tool failure in a manner similar to a temperature
failure.

Taylor Tool Life Equation

n
Vx T =C

V = Cutting speed, T = Tool life, n & C = constant and their values are depend on feed, depth of
cut, work materials, tool material, and tool life criterion used.

6
 4. Drilling
Is a metal removal process where part of metal is removed using a twisting motion with large
force exerted against the workpiece; which causes shearing and extrusion of material chip out of
the created hole.

Principle of drilling

The rotating edge of the drill exerts a large force on the workpiece and the hole is generated.
The removal of metal in a drilling operation is by shearing and extrusion.
When the drill bit is being rotated, a force is applied to it by a weight.

Formula
Vc x 12
RPM = XD (Rev/min)

RPM x x D
Cutting speed = Vc = 12 ( m/min )

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 Feed rate = Vf = IPR x RPM ( m/min )
2 2
Cross-section area of hole AT = x r ( m )
3
Material Removal Rate = Q = Vf x AT ( m /min)
Hp x 5252
Torque = Mc = RPM (ft/lbs)

Experiment Procedure
1. Measured the given Mild Steel round rods length and diameter with the help of steel ruler and

Vernier callipers.
2. Set the long Mild Steel rod in the Lathe machine and tighten it with chuck key.
3. The Lathe machine is turning in a high speed with the long Mild Steel rod and the cutting tool

removed a thin layer of metal from the rod surface slowly.

4. Drill a 10 mm diameter hole and 50 mm long at both centre point of the long Mild Steel rod.
5. Set the short Mild Steel rod at the Lathe machine and tighten it with chuck key.
6. The Lathe machine is turning in a high speed with the short Mild Steel rod and the cutting tool

removed a thin layer of metal from the rod surface slowly.

7. Use the cutting tool to remove 3mm long from the short Mild Steel rod, to get desired length

which is 50 mm.
8. In order to remove 15 mm outer diameter at the first 20 mm long part, we are required to use

the cutting tool to cut its surface in a direction of feed motion and increase its depth of cut

gradually.
9. Repeat the previous step 4-5 times on the short Mild Steel rod.

Results
For 25mm x 50 mm Mild steel rod part, can be considered successful in the cutting section.
8
 Failed in having a 0.5 mm rivet.
For 25mm x 100 mm Mild steel rod part, completed cutting section as well.
Failed in drilling section.

(a) 25mm x 50 mm Mild steel rod (b) 25mm x 100 mm Mild steel rod

Discussion
Lack of experience, knowledge and practical skill always is the biggest obstacle to us. This is also one
of the reason why the drill bit will be broken and