MCB 1043 Manufacturing Technology I

Project 1: Chip-Formation (Butter-Cutting) Lecturer: Dr. Hasan Fawad

Name

: Lee Kian Seng (14739) : Kong Yien Yi (14956)

Course Signature

: Mechanical Engineering : :

Objective: To determine the effects of rake angles of cutting tool and temperatures of work piece on the formation of chips, force required for cutting and chatters effect.

Apparatus and Materials: Knife Tissue Paper Camera

Butter at different temperatures (Melting condition, Room Temperature and Frozen condition)

Procedure: 1. 2. 3. 4. 5. Frozen butter was prepared. The knife was first held at 45 and slowly cut through the surface of the butter. The depth of cut was kept constant. Step 2 was repeated by using the angle of 90 and 135. Step 2 to step 4 were repeated by using butter in room temperature followed by butter in melting condition. 6. The formation of chips at different temperatures of butter and different angles of knife cutting were observed and recorded by taking photo.

Results: 1. Frozen (0C) At 0C, the butter is hard, therefore a large magnitude of force is required to scrap the butter. It is observed that the chips formed are either continuous and twisted in circular manner or deposit on knife or/and butter. Also, chatter is felt when scraping the hard butter. i) 45 cutting angle (tool rake angle)

When the angle is 45, it is relatively easy to scrap the butter, i.e. less force is required. Chip formed is continuous and twisted in circular manner and it does not stick on the surface of knife and butter. Minor chatter is experienced. ii) 90 cutting angle (tool rake angle)

When the angle is 90, force required to scrap the butter is greater than that at 45. Discontinuous chip formed deposits at the knife, forming steps as it sticks on the knife layer by layer. More intense chatter is experienced. iii) 135 cutting angle (tool rake angle)

When the angle is 135, very large force is needed to scrap the butter. Discontinuous chip formed deposits on the knife and the butter due to this 135 orientation. Serious chatter is felt when cutting.

2. Increased temperature (10C) At about 10C, the butter is softer than its frozen state, therefore less force is required to scrap the butter as compared to that at 0. It is observed that the chips formed are discontinuous and in the form of steps. Less intense chatter is felt when scraping the hard butter comparing to that at 0. i) 45 cutting angle (tool rake angle)

When the angle is 45, it is relatively easy to scrap the butter than at greater angles, i.e. less force is required. Chip formed is discontinuous steps and deposits on the surface of knife. Very little chatter is experienced. ii) 90 cutting angle (tool rake angle)

When the angle is 90, force required to scrap the butter is greater than that at 45. Discontinuous chip formed deposits at the knife, forming steps as it sticks on the knife. Minor chatter is experienced. iii) 135 cutting angle (tool rake angle)

When the angle is 135, even larger force is needed to scrap the butter. Discontinuous chip formed deposits on the knife and the butter due to this 135 orientation. The chips are blocking the cutting process. Some chatter is felt when cutting.

3. Room temperature (25C) At about 25C, the butter is quite soft, therefore small force is needed to scrap the butter. It is observed that the chips formed are discontinuous and in the form of steps but less sharp-edged then that at 10C. Very little chatter is felt when scraping the hard butter. i) 45 cutting angle (tool rake angle)

When the angle is 45, it is extremely easy to scrap the butter than at greater angles, i.e. less force is required. Chip formed is discontinuous steps and deposits on the surface of knife. No chatter is experienced. ii) 90 cutting angle (tool rake angle)

When the angle is 90, force required to scrap the butter is greater than that at 45. Discontinuous chip formed in steps form and deposits on the knife. Very little chatter is experienced. iii) 135 cutting angle (tool rake angle)

When the angle is 135, even larger force is needed to scrap the butter. Discontinuous chip formed deposits on the knife and the butter, blocking the cutting process. Minor chatter is felt when cutting. Conclusion: The higher the temperature, the lower the force is required for scraping, less sharp-edged discontinuous chips are formed and less chatter is experienced. The greater the cutting angle (rake angle), the greater force is required for scraping, more chips blockage of cutting process, more layered discontinuous chips are formed and more chatter is experienced.