Adama university

EXPERIMENT P1

METAL CUTTING PROCESS

Objective
• To learn about machining equipment and the metal cutting process.
• To better understand the relationship between metal cutting parameters and other process
Issues that impact cutting force values.
• To observe and understand the progression of chip formation and its machnablity the process

Introduction

As introduction these experiments is used to identified .what is marching mean & what are the
d/t types of parameters used in metal cutting process or marching process?

Metal cutting is manufacering process by which a worker pieces is given a desired shape, a
desired size, desired surfaces finishing .to achieve one or all of these the excess (undesired)
material is removed from the work pieces in the form of chip with the help of some properly
shaped & sized tools. Metal cutting process. Turing is one of the chips forming process & in our
cases truing process are Aluminum & Brass our work pieces & by using HSS tools & try to
identified d/t types of chips deforming the work material on the surfaces of the job with the help
of the marching process we get the following three types which are:

 Continues chip
 Continues chip with BUE & discontinues chip
 Discontinues

Continues chip :during the cutting of ductile material like aluminum, brass alloys c Continues
chip type produced with spare race angle tools the transition of work materials suffers less over
all deformation & the cutting speed ,the primary zone of deformation shapes become narrow.

Continues chip with BUE : high at the interface b/n the tools during cutting also the work
material slide under Haley pressure on the race face before being teraneforemed into a free chip
.there for in the these conditions, some portion of the chip may stick to the race face of the tool.

Built up & breaking of BUE resulting in poor surfaces finishing formed increasing temperance
which softens the BUE.

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Discontinues chip: theses chip are produced during the cutting of brittle materials like cast iron
& brass cutting higher percentage of Zink etc

Discontinues chip formation d/t form continues chip formation in that the work material contact
over the tool race face is over a shirted duration.

During marching of materials which are less brittle (can suffer same plastic deformation, both
continues & discontinues chip may be formed under appropriate condition of rake angle &
cutting speed.

Our cutting tool selections are deepened on cutting tool selection are depends on cutting
parameters & tool geometers.

Cutting eage angle, relief angle, nose readies & rake angle positive rake angle (side &back)
increase the cutting performances of the tool by decreasing cutting forces, work pieces deflector
& power consumption other hand negative rake angle incise cutting forces but make the tool
stager or less liable to fracture or crumbling tool made of very hard & brittle material like
oxides are therefore given negative rake angle where as those made from tough material like
HSS are given positive rake angle .

For the same reason aluminum & brass inserts are sometimes provided with a negative rake
land of a relative narrow width (1-1.5times the feed) which the reaming rake face is positively
inclined.

HSS its hot hardiness is get high so the HSS cutting ability up to 600 ware resistances is high the
hadenablity is good.

Machnablity

Chips may be cut from some materials with relative case & from others with the greater
difficulty.machnablity is high temperature power consuming & high tool wear.

Machnablity of alumni m: Is high chemical compassion than brass of work pieces material.

The physical properties such as tensile strength, ductility & hardens of aluminum material
higher than brass material.

Good surface finish of aluminum can be higher than brass material.

The cutting speed ,metal removal rate of aluminum are higher than brass material.

The low power consumption are brass higher than aluminum.

Figure 1 shows the geometry of the cutting zone and outlines the notation used to describe a bar

Turning operation.

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Experimental Apparatus

1.1. Lathe: Colchester

2. Tail stock
3. Head stock
4. Cross slide
5. Spindle
6. Holding jaws
7. HSS Cutting Inserts
8. Tool holder

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9. Verne caliper
10. Box ranch
11. Alimonies work pieces
12. Brass work pieces
13. Teranceparet paper
14. Coolant
15. Turret
16. Tool post
17. Chuck
18. Work table
19. cutter

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Experimental set up
Woke piece metal: Aluminum, brass, initial diameter 150mm, final diameter
Approximately 40mm length 100mm.
Tool materials suitable for each work material
Cutting parameter are given for marching for brass & ammonium
Depth of cutting a=1.5mm (incremental 0.5mm)
Feed=0.25mm/rev (incremental 80*10-6m)
Seed =120m/min (incremental 15m/min)

Observation
Prepare the proper setting of machine, checks coolant system, cutting speed of machine to
chacke, the capacity & work pieces proper holding.
Decide the Tool Material and then Size, shape, tool signature and model number tool.

Experimental setup of aluminum

Step 1

Depth of Feed Rpm

cutting

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1.5 0.3 280

1.5 0.3 400
1.5 0.3 560
1.5 0.3 800
1.5 0.3 1120
1.5 0.3 1600

Step 2

Depth of Feed Rpm

cutting
1.5 0.075 1120
1.5 0.15 1120
1.5 0.24 1120
1.5 0.3 1120
1.5 0.39 1120
1.5 0.42 1120
Step3

Depth of Feed Rpm

cutting
Feed Rpm
0.5 0.24 1120
1 0.24 1120
1.5 0.24 1120
2 0.24 1120
2.5 0.24 1120
3 0.24 1120

3.5 0.24 1120

Experimental setup of brass

Step1

Depth of Feed Rpm

cutting
Feed Rpm
1.5 0.075 1120
1.5 0.15 1120
1.5 0.24 1120
1.5 0.3 1120
1.5 0.39 1120
1.5 0.42 1120

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Step 2

Depth of Feed Rpm

cutting
Feed Rpm
0.5 0.24 560
1 0.24 560
1.5 0.24 560
2 0.24 560
2.5 0.24 560
3 0.24 560
Step3

Depth of Feed Rpm

cutting
1 0.24 280
1.5 0.24 400
1.5 0.24 560
1.5 0.24 800
1.5 0.24 1120
1.5 0.24 1600

Expemetal procedure
1. Selecting the material using in d/t parameter of the work pieces.
2. Set up the machine proper working conduction.
3. Using by power cutting machine (hesaw) cut the maternal in length of appropriate
measurement.
4. To gather working tool available for Expemetal work that are veneer caliper, box ranch by d/t
size coolant, cutting too HSS & cleaning maternal
5. Clamped work pieces in lathe machine
6. Center work pieces by using tail stock
7. By using of HSS cutting tool marching work pieces d/t mechanism using that is truing, facing to
get peeper demotion & surface finishing.
8. Starting chip formation in the diameter of 50mm
9. Cleaning the lathe machine to observe chip formation in d/t cutting speed, feed rate &varying
diameter by automatic set up formation.
10. Identifying chip formation in d/t cutting speed , feed rate & d/t diameter
11. Gathering information by using oberevacion chip formed & reordering the data by camera.
12. Analyzed you data.

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Cutting condition
Aluminum
Cs=750feet/min=750*304.8/1000

Cs=228.6m/min

Feed=0.012inch=3.14mm

Depth of cutting=0.125=3.175mm

MRR=Cs*f*d

Brass
Cs=300feet/min=300*304.8/1000=91.6m/mm

Feed=0.012inch=0.3048mm

Depth of cutting=0.125inch=3.17mm

Alumnus

Results & discussion

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Time irregular size discontinue

Some fine particle & continue particle formed

Some c shaped formed

Curled average=1-2

Chip thickens =0.2

Chip length average =0.6

Continue
shaped &
BUE formed

Large length
shaped thick

S shaped
formed &
cured

Curled
average=9

Chip length
average=1-13

Chip thickens
=0.2

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Continue & irregular shaped with BUE

S shaped & curled shaped

Size thicker

Curled average=5-6

Chip length average=1-4.4

Chip thickens =0.2

Continue & less irregular shaped with BUE

S shaped & cured

Large size & thickens

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Curled average=3-4

Chip length average=1-2.3

Chip thickens =0.2

Continue & less irregular shaped with BUE

S shaped & c shaped formed

Cured & thicker shaped

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Curled average=6

Chip length average=1-2.5

Chip thickens =0.3

Continues with BUE& less bright

S shaped & c shaped formed

Very highly curled formed

Curled average=1-6

Chip length average=1-9.5

Chip thickens =0.4

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Continues feragemet

S shaped & c shaped formed

Curled formed

Curled average=4

Chip length average=1-2.7

Chip thickens =0.2

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Continues with BUE

Very long Height

Less curled formed

Curled average=9

Chip length average=1-13

Chip thickens =0.2

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Continues with light shine

Cured has formed

S shaped formed Curled average=5

Chip length average=4

Chip thickens =1-6

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Continues with BUE

Cured & tatted shaped formed

Chip thicker formed

Curled average=3

Chip length average=1-2.5

Chip thickens =0.3

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Continues

Curled formed

Chip thicker formed

S shaped formed

Curled average=1-6

Chip length average=1-9.5

Chip thickens =0.4

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Discontinues shared formed

C shaped formed

Less thick size

Curled average=6

Chip length average=3.5

Chip thickens =0.1

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Discontinues shared formed

C shaped formed

Some thicker size

c shaped formed

Chip length average=1-9.5

Chip thickens =0.4

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Discontinues shared formed

C shaped formed

Thicker size C shaped formed

Chip length average=1-9.5

Chip thickens =0.4

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Discontinues shared formed

C shaped formed

Thicker formed

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Discontinues shared formed

C shaped formed

Very highly thicker size

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BRASS

Discontinues

C shaped formed

Less thick size

Little bits shaped

Chip length

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Discontinues

C shaped formed

Thicker size

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Discontinues

C shaped formed

Thicker size

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Discontinues

C shaped formed

Thicker size

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Discontinues

C shaped formed

Thicker size

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Discontinues

C shaped formed

Very fine size

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Discontinues

C shaped formed

Less fine size

Discontinues

C shaped
formed

Less fine size

Discontinues

C shaped
formed

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Less large Thicker size

Discontinues

C shaped formed

Thicker size

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Discontinues

C shaped formed

Very thicker size

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Discontinues

C shaped formed

Thicker size

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Discontinues

C shaped formed

Thicker size

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Discontinues

C shaped formed

Thicker size

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Discontinues

C shaped formed

Thicker size

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Discontinues

C shaped formed

Thicker size

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Discontinues

C shaped formed

Largest c shaped formed size

Conclusions
This experiment concluded that fumed d/t chip formation & d/t cutting parameter used in metal cutting
peeresses

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