Academy of Technology

Department of Mechanical Engineering

Machining and Machine Tools Laboratory

ME-691 (WBUT:-2013→)

Assignments and Lab Experiments 1

Measurement of cutting force components; Pz, Px and Py in straight turning under different
cutting velocities, feeds and environments.

1. Objectives:
 Determination and study of the magnitude and pattern of the cutting force components in
turning by measurement using dynamometer.
 Investigation of the role of variation of the major machining parameters on the cutting
force components.
 Evaluation of yield shear strength of the work material under the machining condition,
power requirement and specific energy consumption.

2. Purpose of Measurement of machining Forces

Energy is invested to accomplish machining by chip seperation. During machining such as
turning, cutting forces act on the cutting tool, chip and the work surface. All those force
components are derived from the three force components.
Pz – Tangential
Px – Axial
Py – Transverse / radial
Which are directly determined by using 2D or 3D turning dynamometer. Attempts should be
made to reduce the magnitudes of the cutting forces (without scarifying productivity and process
capability) to reduce dimensional deviation, surface roughness, energy consumption, cutting
temperature and premature tool failure. Cutting force mesurements are necessary also for
developing models as well as for the testing the validity of analytical models.

3. Theory
Formation and the seperation of the chip is caused by
(a) Yielding or shearing – in case of ductile materials.
(b) Brittle Fracture – in case of brittle materials
 Energy is expanded through the cutting tool to accomplish the deformation by yielding or
fracturing and to overcome the secondary deformation or rubbing forces. As a result the chip,
cutting tool tip and the work surface at the cutting point are subjected to force in different
directions and magnitudes. All those forces are resulted from the three orthogonal force
components Pz, Px and Py which can be directly determined by measurements using suitable
dynamometer. The magnitude of the forces can also be approximately estimated analytically.
However, attempts need to be made to reduce the magnitude of the cutting forces as far as
posible but not at the cost of MMR.

4. Machine and Equipment to be Used

Machine tools – Centre Lathe; NH22, 7.5 KW, HMT Lathe
Equipments –
 A 2D dynamometer (Pre calibrated)
 A strain measuring bridge with data acquisition system
 Slide callipers.

5. Experimental Investigation

(i) Experimental Condition

 Cutting velocity, Vc (m/min): - 40, 60, 80 and 120

 Feeds, S0 (mm/rev): - 0.08, 0.10, 0.12 and 0.16
 Depth of cut, t: - 2.0 mm
 Cutting fluid (environment): - dry, sol oil and neat oil
 Blank material:- mild steel
 Size:- Φ 100 X 250 mm
 Cutting tool:- S4 or P 30
 Material:- sintered carbide inserts
 Geometry:- 120408; -60, -60, 60, 60, 150, 750, 0.8 (mm)

(ii) Experimental Procedure

 Proper mounting of work piece and cutting tool

 Straight turing of the rod at the particular machining condition and record the
force readings.
 Repeat the same at all the selected Vc – S0 combination keeping depth of cut and
environment unchanged.
 Collect the chip samples for all the cuts and measure their average thickness (a 2)
6. Experimental Results
Present the experimental results in tabular form as indicated below.

Table-1 cutting forces under different Vc – S0 combinations

Cutting Feed S0 Pz Px Chip

velocity Vc, mm/rev thickness
SMB N SMB N
m/min a2, mm
reading reading
S01
VcI
So2
So3
So4
S01
Vc2
So2
So3
So4
S01
Vc3
So2
So3
So4
S01
Vc4
So2
S03
So4

7. Evaluation from the experimental results

(a) Drawing marchant’s circle diagram
(b) Dynamic yield shear strength of work material under the cutting condition
(c) Power consumption (Pc) and specific energy consumption at different feed conditions.

(a) Drawing marchant’s circle diagram (MCD) using the experimental data.
Procedural steps:
 Draw the tool – work – chip as shown with given value of orthogonal rake, γ 0
 Select the suitable scale e.g. 1cm = 50 N
 Draw Pz and Pxy in cm along Vc and πR as shown where P xy = Px /Sin Φ
 Draw resultant force R = Pz + Pxy
 Draw the marchant circle taking R as diameter
 Get F and N as intercepts as shown
 Determine shear angle β0 from

 Draw Ps and Pn in the MCD

Fig. 1 Marchan’t Circle Diagram (MCD) with cutting forces

(b) Determine τs under Vc – S0 combination from Pz = tS0 τs f

 (c) Determine power consumption Pc and specific energy consumption, Vc under different Vc –
S0 combination from;
Where f = form factor = ζ - tanγ0 +1

8. Discussion
 On the obtained pattern of the graphs
 On chips; patterns
 On built-up-edge formation
 On quality of machined surface

9. Conclusion



10. Answer the following questions:

i. Show the condition, with the help of ‘MCD’ when P z becomes equal to normal force, N.
ii. If PCEA (Φ) = 900 and Pxy = 400, determine the values of Px and Py.
iii. State the causea and effects of formation of BUE in machining