Machining Science & Metrology

Lab (ME 355)

Department of Mechanical Engineering
Course- Autumn 2020
Objective
Study of Morphology and Mechanism of Chip Formation under
Different Machining Condition(Turning).

Vc=πDN÷1000 m/min; where D is in mm, N is in RPM

Cutting Speed
Feed Rate
(RPM)

Chip Thickness
Theory

Chip formation, part

of material cutting by
mechanical means,
using tools as saws,
lathes, milling cutter,
shaper, planner etc.

Purpose of Studying Morphology & Mechanism of Chip Formation

• Mode of formation ,form of chips, specific energy requirement for a
particular material using specific tool.+
• Optimization of machining parameters.
• Nature or degree of chip-tool interaction : friction, wear, BUE formation
etc.
• Behaviour of work material under different cutting condition.
• Effects of various cutting fluids.
• Cutting edge condition. 3
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Apparatus: NH22 Lathe, C20 steel block, Tool

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Changing the Feed Rate in NH 22 Lathe

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Experimental Details
Chemical Composition of the Work-piece
Elements Percentage (weight)
Carbon 0.07 max
Chromium 19-21
Copper 3-4
Iron Balance
Manganese 2 max
Molybdenum 2-3
Nickel 32-38
Phosphorus 0.045 max
Silicon 1 max
Sulphur 0.035 max
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Input Parameters For Dry & Wet Condition
Sl. No. Spindle Speed(RPM) Feed Rate(mm/rev)

1. 250 0.12

2. 325 0.12

3. 420 0.12

4. 550 0.12

5. 420 0.08

6. 420 0.16

7. 420 0.20

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Chip Morphology Under Different Machining Condition

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Chips obtained under dry condition(const. feed)

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Chips obtained under dry condition(const. RPM)

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Chips obtained under lubricating condition(const. feed)

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Chips obtained under lubricating condition(const. RPM)

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Results: For Dry Machining
Spindle Feed Rate Chip Thickness a2 (mm) Avg. a2
Speed(RPM) (mm/rev)

250 0.12 0.24 0.25 0.20 0.22 0.24 0.23

325 0.12 0.29 0.26 0.26 0.30 0.28 0.27

420 0.12 0.34 0.28 0.27 0.28 0.29 0.25

550 0.12 0.34 0.26 0.29 0.38 0.30 0.29

420 0.08 0.15 0.15 0.19 0.18 0.17 0.16

420 0.16 0.33 0.39 0.35 0.37 0.36 0.38

420 0.20 0.42 0.36 0.43 0.43 0.44 0.41

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Results: With Coolant
Spindle Feed Rate Chip Thickness a2 (mm) Avg. a2
Speed(RPM) (mm/rev)
250 0.12 0.32 0.28 0.23 0.24 0.26 0.27

325 0.12 0.29 0.33 0.33 0.27 0.20 0.30

420 0.12 0.37 0.29 0.33 0.27 0.26 0.34

550 0.12 0.38 0.36 0.34 0.34 0.40 0.35

420 0.08 0.15 0.2 0.23 0.19 0.2 0.18

420 0.16 0.36 0.35 0.36 0.34 0.31 0.36

420 0.20 0.44 0.43 0.41 0.38 0.43 0.42

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Analysis

Tool insert: SPUN 120308

Holder: 0-6-6-6-15-75-08 (mm) [ORS]
Depth of cut:0.5mm
Environment: Dry/Wet Soluble Oil

❑Vc=πDN÷1000 m/min; where D is in mm, N is in RPM

❑ Uncut chip thickness(a1)=So*sinφ

❑ Chip reduction coefficient(ζ)=a2/a1

❑ tanβo = cosγo /(ζ-sin γo), where βo is the shear angle

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Dry Machining [D=74.25mm]
Speed Vc So a1 a2 Colour Form ζ= a2/a1 Shear
(RPM) (m/min) (mm/rev) (So*sin75°) angle
(βo)
250 0.12

325 0.12

420 0.12

550 0.12

420 0.08

420 0.16

420 0.20
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With Coolant [D=73.25mm]
Speed Vc So a1 a2 Colour Form ζ= a2/a1 Shear
(RPM) (m/min) (mm/rev) (So*sin75°) angle
(βo)
250 0.12

325 0.12

420 0.12

550 0.12

420 0.08

420 0.16

420 0.20
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Assignments (for both dry & under lubrication)

1. Plot graph of Vc vs CRC

2. Plot of Vc vs βo

3. So vs CRC

4. So vs βo

5. Draw conclusions from your findings

Mail your results to phd1901203005@iiti.ac.in

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Dry Condition
RPM 250 Feed Rate 0.12

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RPM 325 Feed Rate 0.12

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RPM 420 Feed Rate 0.12

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RPM 550 Feed Rate 0.12

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RPM 420 Feed Rate 0.08

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RPM 420 Feed Rate 0.12

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RPM 420 Feed Rate 0.16

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RPM 420 Feed Rate 0.20

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Under Lubrication

RPM 250 Feed Rate 0.12

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RPM 325 Feed Rate 0.12

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RPM 420 Feed Rate 0.12

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RPM 550 Feed Rate 0.12

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RPM 420 Feed Rate 0.08

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RPM 420 Feed Rate 0.12

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RPM 420 Feed Rate 0.16

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RPM 420 Feed Rate 0.20

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