Cutting forces study

Most of the manufacturing process involve some sort of cutting operations in either final or initial stage
of product development. A cutting tool is utilized for the purpose material removal. A cutting tool
removes material by doing shear deformation. Cutting tools available can be of single point cutting tool
or multi point cutting tool. Single point cutting tool are used in turning, shaping, etc. operation while
multipoint cutting tools are used in milling, drilling, etc.
Cutting tool are always made of harder material than the material to be removed from the product. Also
cutting tools have predefined geometry. For achieving desired material removal rate various cutting
parameters are changed and adjusted so as to achieve appropriate finish quality and rate of production.
These parameters are mainly

Feed rate(f)
Depth of cut(d)
Speed (s)

Feed rate is the movement of the tool in one complete rotation of spindle in turning operation. Depth of
cut is the distance by which tool penetrates into the workpiece. Speed is the rate of rotation for spindle.
Various models are suggested to study the cutting operation by a tool. Simplest is the orthogonal cutting
model in which tool geometry is defined by rake angle and clearance angle. The diagram shows the
model description and chip formation in cutting operation.

SOURCE: M. Groover, fundamentals of modern manufacturing, 4th Ed.

Force is required to deform any material. To remove material using shear deformation cutting tool
applied consider amount of force so that the material deforms. These forces also acts on the tool but as
reaction to the applied forces. These forces can damage and reduce the tool life. Higher forces also
implies higher power input. Thus objective of any cutting operation is to minimize the cutting forces so
that minimum input energy is required by adjusting the cutting parameters. The diagram show the
forces acting on the cutting tool.

SOURCE: M. Groover, fundamentals of modern manufacturing, 4th Ed.

Fc=cutting force
Ft=thrust force
R=net reaction
These forces are for only orthogonal cutting model. However cutting really takes place in 3D thus forces
are also present in 3D. Also moments generate because of forces in 3D.
A CNC lathe is used for studying forces and moments on the tool in the turning operations. The cutting
parameters selected are
f=0.5/0.7 mm/rev
d=0.7/1.0 mm
Which gives us 4 combinations with same spindle speed for each case. The data is plotted to check the
variation in cutting forces. Sampling starts at the start of cutting operation. In some cases sampling is
delayed due to human error.
OBSERVATIONS:
the graph plotted are for Forces in X Y Z direction and Moments in X Y Z direction.
X direction radial in horizontal plane
Y direction radial in vertical plane
Z direction in axial direction of spindle

FX
150

FORCE(N)

100
50

F.5D.7

F.5D1.0

-50 0

100

200

300

400

500

600

700

800

-100

F.7D.7
F.7D1.0

-150

TIME(S)

FY
300

FORCE(N)

200
F.5D.7

100

F.5D1.0

0
-100

100

200

300

400

500

600

700

800

F.7D.7
F.7D1.0

-200

TIME(S)

FZ
0.08
0.06

FORCE(N)

0.04
0.02

F.5D.7

0
-0.02 0

100

200

300

400

600

700

800

F.5D1.0
F.7D.7

-0.04

F.7D1.0

-0.06
-0.08
-0.1

500

TIME(S)

MX

MOMENT(Nm)

10
5
F.5D.7
F.5D1.0

100

200

300

400

500

600

700

800

-5

F.7D.7
F.7D1.0

-10

TIME(S)

MY
2

MOMENT(Nm)

1
0
-1

F.5D.7
0

100

200

300

400

500

600

700

800

F.5D1.0
F.7D.7

-2

F.7D1.0

-3
-4

TIME(S)

MZ
20

MOMENT(Nm)

15
10
F.5D.7

F.5D1.0

0
-5 0

100

200

300

400

-10

600

700

800

F.7D.7
F.7D1.0

-15
-20

500

TIME(S)

Force in x direction increase with increase in feed rate

Force in y direction decreases with increase in feed rate (absolute value increase)
Force in z direction increases with increase in feed rate

Moment in x direction decreases with increase in feed rate ((absolute value increase)
No significant change is observed in moment in y direction
Moment in z direction increases with increase in feed rate
These results obtained are as per the theory. Variation with respect to feed rate is satisfactory. More
feed rate imply more material removal implying more forces.
Conclusion cannot be derived for variation in depth of cut since the normalizing area for each plot
differs greatly.

GROUP MEMBERS (G5-A)

AVI RAJPUT
AASHISH BHARDWAJ
AASHISH KUMAR KHOLIYA
ADARSH KUMAR
ADITYA GOYAL