Assessment Cover Sheet

Faculty of Engineering

Module Details
Module Code ME3100 Module Title MANUFACUTRING PROCESS II
Program: SLIIT Course: BSc
Stream: Mechanical

Assessment details
Title MEASUREMENT OF Group assignment NO
CUTTING FORCES If yes, Group No.
Lecturer/ Instructor MS. BUDDHIMA WANAGURU Date of Performance 27/02/2019
Due date 06/02/2019 Date submitted 06/02/2019

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EN17353458 GAMAGE O.D.

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 Measurement of Cutting Forces
Manufacturing Process II
ME3100

Department of Mechanical Engineering

Sri Lanka Institute of Information Technology
Malabe

Name: Gamage O.D.

Reg. Number: EN17353458
Group: 02
Program: SLIIT/ UGC

Instructed By: Ms. Buddhima Wanaguru

Date of Performance: 27/02/2019
Date of Submission: 06/02/2019
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Objectives
 To monitor cutting forces of lathe machining.
 To identify Lathe tool dynamometer and its application.
 To study cutting forces with different materials and tool geometries.

Equipment

 Lathe machine.
 Lathe Tool Dynamometer.
 Turing tools with different rake angle.

Introduction

A process of turning is a process of machining cylindrical parts. As the workpiece rotates, the tool
normally moves along the main axis (z). When set up with a lower diameter than the workpiece's
actual, it reduces its diameter by cutting the workpiece's "surface." This operation is normally used
only to remove material from the flat face (facing) or to remove a specific part from the total length
(cut-off). The cutting operation is produced by displacing the tool, removing a thin surface section
reduces the workpiece's diameter. The figure below shows a diagram of the standard turning process
forces, where the parallel direction of the cutting tool and the spindle velocity can also be seen.

Figure 1. The cutting forces acting on the workpiece.

When a good accuracy and surface finish needs to be achieved, some considerations need to be
addressed. To maintain a good operating quality, clamping stability and correct center height are two
of these important factors. The height of the center affects the rake angle as well as the tool's cutting
force. Proper clamping must be exceptional when machining with long overhangs, but possible
dimensional errors must be considered due to deflection of the tool or workpiece.
A lathe tool dynamometer has been designed and developed to evaluate fixed cutting forces using the
level of strain gauges. During operations such as facing, turning, the designed lathe tool dynamometer
can calculate the forces on the cutting tool. The sensing system measures deflection in strain gages and
these signals are changed into other quantities and calculated in the display system in the form of
forces.
Cutting Force (Fc) - This force has primary effect on motion and has 70%-80% of total force over the
operation and used to calculate power for machining.
Feed Force (Ff) - This force works in the direction of feed motion. Cutting forces changes linearly with
feed at high speed but change is exponential at slower speeds.
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Radial Force (Fr) - Radial force works in the direction perpendicular to feed force (Ff). This force has
lesser effect compared to the other two forces.
Lathe Tool Dynamometer

Figure 2. A Tool Lathe Dynamometer.

Dynamo meter lathe tool working principle,
Lathe tool dynamo meter is a device that uses strain gauges to observe the amount of load that acts on
the tool during operation. The sensor is mounted rigidly on the tool post and the cutting tool can be
attached directly to the sensor.
Merchants theory

Figure 2. Merchants Circle.

Merchant's Circle Diagram is designed to facilitate the analysis of cutting forces during orthogonal
(Two Dimensional) workpiece cutting. This scientific analysis was carried out for the first time in
1941 by Ernst and Merchant and gives the following relation in 1944. It is advisable to determine
different strengths and angles.
𝝅 𝟏
∅= − (𝝀 − 𝜶)
𝟒 𝟐
Assumptions of the merchant’s theory,
 The edge of the tool is very sharp.
 Work material undergoes thin shear plane deformation.
 Normal and shear stress distribution on the shear plane is consistent.
 The material used in the work is rigid and perfectly plastic.
 The shear angle is adjusted to minimize the work.
 The width of the chip remains constant.
 The chip is not flowing side by side.
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Procedure

 The dynamometer was securely mounted on the tool post.

 Then the tool was grinded to have a sharp positive rake angle.
 Then the tool was fixed on the dynamometer using 4 Allan screws.
 Then the processing unit was connected to the processing unit by USB connecter.
 After that the tool viewer program was installed.
 Then the processing unit was set as per the initial operating instructions.
 Finally, the reading was taken by operating the lathe machine.
Results

Material Mild Steel

Cutting Speed Depth of cut Cutting Force Feed force (Ff) Radial Force (Fr)
m/min mm (Fc) N N N
0.2 7 18 15
100
0.4 21 7 13
0.2 1 2 1
500
0.4 15 7 10
Table 1. Results of Mild steel.

Material Aluminum
Cutting Speed Depth of cut Cutting Force Feed force (Ff) Radial Force (Fr)
m/min mm (Fc) N N N
0.2 6 1 4
100
0.4 3 1 2
0.2 4 1 3
500
0.4 4 1 3
Table 2. Results of Aluminum.

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Discussion.
There are 3 cutting forces acting on the workpiece. These forces are acting along the 3 axes on the
workpieces.
X axis – Feed force
Y axis – Radial force
Z axis – Cutting force
The basic step in determining and controlling the conditions under which the machine, the tool, and the
workpiece, when the workpiece is machining is to measure cutting forces during machining processes.
By measuring cutting forces during machining, it is possible to estimate operating temperatures, tool
wear and power consumption, the deflections of the workpieces, and the areas of not cutting among
other properties that are important for improving the process. There are two ways of measuring forces;
online and offline, but in this case the forces are measured online. Online measuring of these
parameters is required to estimate and control the quality of the finished product as well as the quality
of the finished product. A lathe tool dynamometer is used to measure cutting forces. The existence of
forces and the magnitudes cannot be directly detected or quantified but can only be detected by their
effects. A force that cannot be seen, but can be detected and quantified by its effects and the quantity
of those effects (on some material) such as elastic deflection, deformation, pressure, strain etc. These
effects, called signals, often require proper conditioning to detect and measure easily, accurately and
reliably. The process of measuring cutting forces consist of basic three steps they are,
Step 1 - By using the appropriate sensors the force is converted proportionally to another variable
(voltage). This voltage is called a signal.
Step 2 - The noisy signal is amplified, filtered, rectified and stabilized for convenience and accuracy of
measurement.
Step 3 – The signal (say voltage) is quantitatively determined and recorded using units such as
galvanometer, oscilloscope, recorder or micro controller.
Measurement of cutting forces are based on three basic principles. They are,
 Measurement of elastic deflection of a body that is subjected to cutting force
 Measurement of elastic deformation induced by the force
 Measurement of pressure developed by the force in a medium.
The tool strain deflection by dial gauge, calibration is performed by using known loads, W and the
corresponding deflections of the tool are deflections, δ are noted and then plotted. Here the curve slope
represents the equation's constant, k. Then while the actual measurement of the cutting force, PZ, is
noted and the corresponding force is evaluated as shown from the plot. The cutting force causes a
proportional deflection of the tool in the capacitive pick - up type dynamometer, resulting in a change
in the gap (d) and thus capacity (C).

𝛿 = 𝑘𝑃𝑍
𝜀𝐴
𝐶=
3.6𝜋𝑑
The change in C is then measured in voltage, ΔV which is proportional to the force. Calibration
determines the final relationship between PZ and ΔV.
The process of setting up the dynamometer,
 Work piece was mounted to the chuck of the lathe.
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  Then the tool dynamometer is mounted on the carriage at the tool holder place.
 The holder of the tool is connected to the dynamometer by a data transfer cable.
 Dynamometer output (forces related to each axis) was displayed in the display.
Dynamometers are often used for testing engines as an example. Engineers can determine how to
increase the efficiency of the engine by measuring the power transfer at various vehicle points. In the
construction world, dynamometers are also quite useful. They could be used to assist workers in
mounting bridge cables and modifying the wires tension known as the tension dynamometer is the type
of tool that can perform these tasks. This tool can be a useful resource when a person is required to
measure an object's strength or tension. All dynamometers are equipped with advanced and accurate
technology, and even the smaller devices are equipped with this quality. They can measure an object
with remarkable precision. Plus, as they are made of strong metal alloys, they can handle large
amounts of force as well.
The forces are varying according with the cutting speed and the material of the workpiece. The cutting
forces have been reduced with the material. The cutting forces are higher for mild steel and
comparatively low for aluminum due to the hardness of the material. For steel the tensile, shear, and
tangent modulus is 3 times the aluminum. Even though the cutting forces have varied with cutting
speeds the experiments have shown that cutting speeds have minor effect on cutting force, but we can
assume that according to the results we obtained there can be relationship between cutting force and
cutting speed. In our case the cutting forces have been reduced with increasing cutting speeds.
There are many errors contributing to the accuracy of the experiment. The main error occurred when
reading the force parameters from the viewer. The forces were fluctuating every time and a mean value
was obtained. By following this procedure results can be different from person to person. By obtaining
a mean valve for large amount of readings can increase the accuracy of the force readings. The
workpieces were not smooth, and the workpiece was deflected which in result contributed the results
to be very erroneous due to the deflection. A dial gauge must be used to center the workpiece properly
before starting the experiment. The condition of the tool tip must also contribute to the accuracy of the
readings where worn out tool will increase cutting forces due to increased friction. The tool must be
grinded before obtaining each set of results.

Conclusion
There are 3 cutting forces acting on a workpiece when machining. These cutting forces will change
according to the material of the workpiece. A slight influence of the cutting speed will have on cutting
forces. A tool lathe dynamometer is used to obtain the results and dynamometers have lot of
advantages. There are several errors which contributes to the accuracy of the experiment.
References
 Home.iitk.ac.in. (2019). [online] Available at: http://home.iitk.ac.in/~vkjain/L6-TA-
202%20MECHANICS%20OF%20CUTTING.pdf [Accessed 2 Mar. 2019].
 Anon, (2019). [online] Available at:
https://www.researchgate.net/publication/321184233_APPLICATION_OF_TAGUCHI_MET
HOD_FOR_OPTIMIZATION_OF_PROCESS_PARAMETERS_IN_ANALYZING_THE_CU
TTING_FORCES_OF_LATHE_TURNING_OPERATION [Accessed 2 Mar. 2019].
 Anon, (2019). [online] Available at: https://www.researchgate.net/figure/Measurement-of-
Forces-using-Lathe-Tool-Dynamometer_fig1_321184233 [Accessed 2 Mar. 2019].

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 sak (2019). LATHE TOOL DYNAMOMETER. [online] Slideshare.net. Available at:
https://www.slideshare.net/sathishsak/lathe-tool-dynamometer [Accessed 2 Mar. 2019].
 Shrivastava (2019). Merchant's circle. [online] Slideshare.net. Available at:
https://www.slideshare.net/SumitShrivastava5/merchant-circle-001-1 [Accessed 2 Mar. 2019].

 Spinning, W. (2019). Steel vs Aluminum: Weight, Strength and Cost Differences | Wenzel
Metal Spinning. [online] Wenzelmetalspinning.com. Available at:
https://www.wenzelmetalspinning.com/steel-vs-aluminum.html [Accessed 2 Mar. 2019].