ME361A LAB REPORT

Experiment number :1

Group number : C1

Roll numbers and Names :

160459 Nitendra Dhakar
160452 Nikhil Prakash
160451 Nikhil Panwar
160465 Omprakash Malani
160468 Pallav Kulhari

Date experiment was conducted on : 9/8/2018

Date of submission of report : 21/8/2018

Objective(s):
(1) To measure cutting forces
(2) To identify cutting force coefficients
(3) To estimate the cutting force coefficient from the estimated chip thickness
Ratio.
(4) To study the influence of cutting speed on cutting forces.
Schematic diagram of the experimental setup

Observations:

Workpiece material: Aluminium (Shear Strength: 3.03 * 10 8 N/m2 )

Outside diameter: 66.5 mm
Depth of cut: 1.25 mm

Table 1: Measurement of forces in the x, y, and z-directions [for constant cutting speed]

Run Feed rate Cutting Spindle AvgFx AvgFy AvgFz

mm/rev speed speed
(m/min) (rev/min)
1 0.075 150 718 54.67 23.98 106.76
2 0.125 150 718 78.43 38.01 154.46
3 0.175 150 718 97.32 51.14 194.34
4 0.225 150 718 114.56 65.64 231.12

Table 2: Measurement of forces in x, y, z directions(for constant feed)

Run Feed rate Cutting Spindle AvgFx AvgFy AvgFz

speed speed
1 0.125 100 479 89.64 45.79 163.05
2 0.125 150 718 78.43 38.01 154.46
3 0.125 200 957 69.31 34.23 141.3
4 0.125 250 1195 57.8 25.15 123.2
 Answers to questions asked in the report:
(1) The plots of Measured Forces along all directions:

Series 1=Fz, Series 2=Fx, Series 3=Fy

Constant Cutting Speed - Run 3 [Feed = 0.175 mm/rev]

Constant Cutting Speed - Run 2 [Feed = 0.225 mm/rev]

350

300

250

200
Series1
150 Series2
Series3
100

50

0
186
371
556
741
926

2776
1111
1296
1481
1666
1851
2036
2221
2406
2591

2961
3146
3331
3516
1

-50
Constant Feed Rate - Run 1 [Cutting speed = 100 m/min]

250

200

150
Series1
100 Series2
Series3
50

0
361
721

3961
1081
1441
1801
2161
2521
2881
3241
3601

4321
4681
5041
5401
5761
6121
6481
6841
1

-50

(2) Averaged force data vs. feed rate at constant cutting speed
 Force vs cutting speed
180
160
140 Fx
120 Fy
100
Fz
80
Linear (Fx)
60
Linear (Fy)
40
Linear (Fz)
20
0
0 50 100 150 200 250 300

The components of force get reduced with the increasing cutting speed.

3. Experimental values of cutting force coefficients

Ft = Ktbh = Fz;
Ff = Kfbh = Fx;
Fr = Krbh = Fy;
Where,
b=chip width = depth of cut = 1.25 mm
h=uncut chip thickness = feed rate

for constant cutting speed of 150 m/min

b (mm) Feed rate AvgFx AvgFy AvgFz Kf Kr(N/mm2) Kt(N/mm2)

mm/rev (N/mm2)
1.25 0.075 54.67 23.98 106.76 583.1467 255.7867 1138.773
1.25 0.125 78.43 38.01 154.46 501.952 243.264 988.544
1.25 0.175 97.32 51.14 194.34 444.8914 233.7829 888.4114
1.25 0.225 114.56 65.64 231.12 407.3244 233.3867 821.76

For constant feed

b (mm) Feed rate Cutting AvgFx AvgFy AvgFz Kf Kr Kt(N/mm2)

speed (N/mm2) (N/mm2)
1.25 0.125 100 89.64 45.79 163.05 573.696 293.056 1043.52
1.25 0.125 150 78.43 38.01 154.46 501.952 243.264 988.544
1.25 0.125 200 69.31 34.23 141.3 443.584 219.072 904.32
1.25 0.125 250 57.8 25.15 123.2 369.92 160.96 788.48
4. Theoretical estimation of cutting coefficients

averagehc = (0.164+0.153+0.207)/3
= 0.175 mm
Feed hc chip φn βn Kf Kr
h Kt
Run Rate (mm) (mm) thickness (rads) (rads) (N/m2) (N/m2) (N/m2)
(mm/rev) (avg.) ratio (rc)

1 .075 .175 .012 .080 .06 1.11 1.61e9 4.56e7 1.9e9

2 .125 .175 .02 .121 .094 1.08 7.24e8 4.36e7 1.45e9

3 .175 .175 .027 .169 .135 1.04 3.91e8 4.14e7 1.11e9

4 .225 .175 .036 .217 .18 .99 2.02e8 3.99e7 9.05e8