0708-F-035 LATHE MACHINE OPTIMUM CUTTING SPEED FOR DIFFERENT

MATERIALS
ANG LIQI
A report submitted in partial fulfillment of
The requirements for the award of the degree of
Bachelor of Mechanical Engineering
With Manufacturing Engineering
Faculty of Mechanical Engineering
UNIVERSITI MALAYSIA PAHANG
NOVEMBER 2008
ii
SUPERVISORS DECLARATION
We hereby declare that we have checked this project and in our opinion this project is
satisfactory in terms of scope and quality for the award of the degree of Bachelor of
Mechanical Engineering with Manufacturing Engineering.
Signature :
Name of Supervisor: LEE GIOK CHUI, SMP, KMN
Position : Lecturer of Faculty Mechanical Engineering
Date :
Signature :
Name of Panel : SALWANI BINTI MOHD SALLEH
Position : Lecturer of Faculty Mechanical Engineering
Date :
iii
STUDENTS DECLARATION
I hereby declare that the work in this thesis is my own except for quotations and
summaries which have been duly acknowledged. The thesis has not been accepted
for any degree and is not concurrently submitted for award of other degree.
Signature :
Name : ANG LIQI
ID Number: ME05067
Date :
iv
To my Beloved Mother and Father
LEE SIEW DUAN
ANG TECK YOKE
v
ACKNOWLEDGEMENT
In preparing this thesis, I was in contact with many people, researchers,
academicians, and practitioners. They have contributed towards my understanding
and thoughts. In particular, I wish to express my sincere appreciation to my thesis
supervisor, Mr. LEE GIOK CHUI, SMP, KMN; Lecturer of Faculty Mechanical
Engineering for encouragement, guidance, critics and friendship. I am also very
thankful to my Academic Advisor, Mr MAHENDRAN A/L SAMYKANO for his
guidance, advices and motivation. Without their continued support and interest, this
thesis would not have been the same as presented here.
I am also indebted to Universiti Malaysia Pahang (UMP) for my degree
study. Librarians and lab assistants at UMP also deserve special thanks for their
assistance in supplying the relevant literatures and help.
My fellow undergraduate students should also be recognised for their support.
My sincere appreciation also extends to all my friends and others who have provided
assistance at various occasions. Their views and tips are useful indeed.
Unfortunately, it is not possible to list all of them in this limited space.
Finally, I am grateful to all my family members especially my parents, Ang
Teck Yoke and Lee Siew Duan. I acknowledge my sincere indebtedness and
gratitude to my parents for their love, dream and sacrifice throughout my life. I
cannot find the appropriate words that could properly describe my appreciation for
their devotion, support and faith in my ability to attain my goals.
vi
ABSTRACT
In today's rapidly changing scenario in manufacturing industries,
applications of optimization techniques in metal cutting processes was essential for a
manufacturing unit to respond effectively to severe competitiveness and increasing
demand of quality product in the market. Optimization methods in metal cutting
processes, considered to be a vital tool for continual improvement of output quality
in products [1]. This study focused in finding the optimum cutting speed that will
produced the best surface finish for different materials. Lathe machine was used to
conduct the experiment. Selecting the wrong cutting parameter may lead to several
negative effects. For example: high maintenance cost of the Lathe machine, poor
surface finish of the work pieces, short tool life, low production rate, material waste
and increase production cost. In order to find out the optimum cutting speed for each
material, there were other cutting parameters needed to be constant, such as feed rate,
depth of cut and workpiece diameter. In machining operation, the quality of surface
finish was an important requirement for many turned workpieces. Thus, the choice of
optimized cutting parameters was very important for controlling the required surface
quality. The focus of this study was to find a correlation between surface roughness
and cutting speed. [2]
vii
ABSTRAK
Dengan perkembangan pesat dalam industri pembuatan pada masa kini,
penerapan teknik optimum dalam proses pemotongan logam adalah mustahak bagi
pekilang-pekilang. Ini akan membolehkan mereka memberi respons yang berkesan
bagi tujuan persaingan dan menambah bagi tujuan persaingan dan menambah
tuntutan hasil perkilangan yang berkualiti dalam pasaran. Kaedah mengoptimumkan
proses pemotongan logam dipandang sebagai cara yang penting demi kemajuan
kualiti yang berterusan bagi hasil perkilangan.Pengajian ini menumpu untuk
mendapatkan kelajuan memotong optimum yang akan menghasilkan keadaan
permukaan yang terbaik bagi bahan berbeza.Mesin Lathe telah digunakan dalam
eksperimen. Pemilihan parameter pemotongan yang salah akan mendatangkan
beberapa kesan negatif. Contohnya, kos pengekalan mesin Lathe yang tinggi,
keadaan permukaan bahan yang tidak bagus, alat potong cepat haus, kadar
penghasilan yang rendah, pembaziran bahan dan penambahan kos penghasilan.Untuk
mendapat kelajuan memotong yang optimum, terdapat beberapa parameter
pemotongan yang lain perlu dimalarkan, contohnya, kadar feed, kedalaman
pemotongan dan diameter bahan yang akan dipotong. Dalam operasi mengenai
penggunaan mesin, kualiti permukaan bahan selepas dimesin adalah keperluan yang
penting. Justeru, memilih parameter pemotongan yang optimum adalah penting
untuk mengawal kualiti permukaan bahan selepas dimesin. Peralatan yang paling
biasa diguna ialah Perthometer. Tumpuan penyelidikan ini adalah untuk
mendapatkan hubung kait antara kelajuan pemotongan dan kekasaran permukaan
bahan selepas dimesin.
viii
TABLE OF CONTENTS
CHAPTER TITLE PAGE
TITLE i
SUPERVISORS DECLARATION ii
STUDENTS DECLARATION iii
DEDICATION iv
ACKNOWLEDGEMENTS v
ABSTRACT vi
ABSTRAK vii
TABLE OF CONTENTS viii
LIST OF TABLES xi
LIST OF FIGURES xii
LIST OF SYMBOLS/ ABBREVIATIONS xiii
CHAPTER 1 INTRODUCTION
1.1 Introduction
1.1.1 Background
1
2
1.2 Problem Statement 2
1.3 Scope of Study 3
1.4 Objective 3
CHAPTER 2 LITERATURE REVIEW
2.1 Introduction 4
2.2 Lathe Machine 4
ix
2.2.1 Description
2.2.2 Choosing a cutting tool
5
5
2.3 Turning Process
2.3.1 Turning Speeds & Feeds
2.3.2 Summary of Turning Parameters and Formulae
7
7
7
2.4 Facing Process 9
2.5 Basic of metal cutting
2.5.1 Cutting process
2.5.2 Cutting forces
10
11
11
2.6 Chip formation
2.6.1 Continuous
2.6.2 Built up edge
2.6.3 Serrated or segmented
2.6.4 Discontinuous
12
12
12
13
13
2.7 Tool wear and surface roughness 15
CHAPTER 3 METHODOLOGY
3.1 Introduction 16
3.2 Methodology flowchart
3.2.1 flowchart
16
17
3.3 Usage of Lathe machine
3.3.1 Safety precautions for lathes
3.3.2 Installing a cutting tool
3.3.3 Positioning the tool
18
18
19
19
3.4 Cutting speed selection for the three materials
3.4.1 Guild line while selecting cutting parameters
3.4.2 Characteristics of selected materials
3.4.3 RPM selection
20
21
21
25
3.5 Constant parameters 25
3.6 Data analysis
3.6.1 Surface roughness measurement
26
26
x
3.6.2 Surface Roughness Calculation 27
3.7 Expected result 28
CHAPTER 4 RESULTS AND DISCUSSION
4.1 Introduction 29
4.2 Analysis of the surface roughness values respond to the changes
of the cutting speed for Brass.
29
4.3 Analysis of the surface roughness values respond to the changes
of the cutting speed for Aluninium.
33
4.4 Analysis of the surface roughness values respond to the changes
of the cutting speed for Mild steel.
38
4.5 Optimum Cutting Speed for Brass, Aluminium and Mild Steel. 42
4.6 Relationship Between Cutting Speed and Surface Finish 43
4.7 Surface roughness difference between turning process and facing
process using the same cutting speed.
44
CHAPTER 5 CONCLUSION AND RECOMMENDATIONS
5.1 Introduction 46
5.2 Conclusion 46
5.3 Recommendations 47
REFERENCES 48
APPENDICES 49
A Machine and Apparatus used in the experiment. 50
B Example of chips produced during machining. 51
C Usage of Perthometer. 52
xi
LIST OF TABLES
Table No. Page
3.1 Cutting Speeds for Various Materials in Surface Feet per Minute 20
3.2 Cutting Speed for different materials with various diameter 21
3.3 The RPMused in the experiment 25
4.1 Average surface roughness value of brass after turning and
facing process at 990rpm.
29
4.2 Average surface roughness value of brass after turning and
facing process at 1305rpm.
30
4.3 Average surface roughness value of brass after turning and
facing process at 1600rpm.
31
4.4 Average surface roughness value of aluminium after turning and
facing process at 1305rpm.
34
4.5 Average surface roughness value of aluminium after turning and
facing process at 1600rpm.
34
4.6 average surface roughness value of aluminium after turning and
facing process at 2570rpm.
35
4.7 Average surface roughness value of mild steel after turning and
facing process at 505rpm.
38
4.8 Average surface roughness value of mild steel after turning and
facing process at 625rpm.
38
4.9 Average surface roughness value of mild steel after turning and
facing process at 815rpm.
39
4.10 Optimum Cutting Speed for Brass, Aluminium and Mild Steel. 42
xii
LIST OF FIGURES
Figure No. Page
2.1 Important parts for lathe machine 4
2.2 Relationship between cutting speed and material with different
hardness.
7
2.3 Relationship between cutting speed and different tool bit used. 7
2.4 Chip formation process 11
2.5 Cutting forces acting on the cutting tool during turning. 12
3.1 Perthometer 26
4.1 Graph of brass turning process using different RPM 31
4.2 Graph of brass facing process using different RPM 32
4.3 Graph of brass turning process vs. facing process using different
RPM.
33
4.4 Graph of aluminium turning process using different RPM 36
4.5 Graph of aluninium facing process using different RPM 36
4.6 Graph of aluminium turning process vs. facing process using
different RPM.
37
4.7 Graph of mild steel turning process using different RPM 40
4.8 Graph of mild steel facing process using different RPM 40
4.9 Graph of mild steel turning process vs. facing process using
different RPM.
41
4.10 Turning process 45
4.11 Facing process 45
xiii
LIST OF SYMBOLS/ ABBREVIATIONS
N Rotational speed of the workpiece
f Feed
v Feed rate, or linear speed of the tool along workpiece length
V Surface speed of workpiece
l Length of cut
Do Original diameter of workpiece
Df Final diameter of workpiece
Davg Average diameter of workpiece
d Depth of cut
t Cutting time
Ra Average deviation of mean surface
Rt Maximum roughness height
Rz Root mean square value
SFPM Surface feet per minute
MRR Material removal rate
FEM Finite element analysis
BUE Built-up-edge
1
CHAPTER 1
INTRODUCTION
1.1 INTRODUCTION
This project is to investigate the Lathe Machine optimum cutting speed for
the three chosen materials. Previous research done on the impact of cutting
parameters that affect surface roughness suggest us that among cutting
parameters(cutting speed, feed rate, and depth of cut), cutting speed has the biggest
impact on the surface roughness [3].Cutting speed is defined as the speed at which
the work progress with respect to the tool . Feed rate is defined as the distance the
tool travels during one revolution of the part. Besides surface finish, Cutting speed
and feed also determine the power requirements and material removal rate. The
primary factor in choosing feed and speed is the material to be cut. However, one
should also consider material of the tool, rigidity of the work piece, size and
condition of the lathe, and depth of cut.[4] In high-volume production, machining
parameters have amplified impacts on the machine performance in terms of
productivity (cycle time), reliability (tool life), and product quality (surface finish).
In addition, production parameters become critical in high-volume production since
they directly impact the overall order fulfillment (production makes pan and delivery
reliability)[1].The three material with different hardness are chosen in this project ,
they are Aluminum, Mild steel and Carbon steel. [4]
2
1.1.1 Background:
Metal cutting is one of the important and widely used manufacturing
processes in engineering industries. The study of metal cutting focuses, among others,
on the features of tools, input work materials, and machine parameter settings
influencing process efficiency and output quality characteristics (or responses). A
significant improvement in process efficiency may be obtained by process parameter
optimization that identifies and determines the regions of critical process control
factors leading to desired outputs or responses with acceptable variations ensuring a
lower cost of manufacturing [1]. Cutting conditions include cutting speed, feed,
depth of cut and cutting fluids. For a machining process such as turning, the cutting
conditions play an important role in the efficient use of a machine tool. There is an
economic need to operate these machines as efficiently as possible in order to obtain
the required payback. Since the cost of turning on these machines is sensitive to the
cutting conditions, optimum values have to be determined before a part is put into
production. This need is even greater in the case of rough machining since a greater
amount of material is removed thus increasing possible savings. The optimum
cutting conditions in this context are those which do not violate any of the constraints
that may apply on the process and satisfy the economic criterion.[5]
In order to determine the optimum cutting conditions, one has to estimate the
tool life and cutting forces with a reasonable degree of accuracy since many of the
constraints that may apply on the process are influenced by these parameters. For a
practical machining situation, since no adequate machining theory is available to
predict the tool life and cutting forces, one is compelled to rely on empirical
equations to predict these parameters. However, these empirical equations involve a
number of constants which are not readily available. Furthermore these constants
depend on many factors thus requiring a huge amount of data for a general workshop
situation. To obtain and manage such a huge amount of data is an extremely difficult
task. Therefore an alternative to this empirical approach that can be used to predict
cutting forces, tool life, etc. will be of great value. [5]
3
1.2 PROBLEM STATEMENT
Select the wrong cutting speed for each material may lead to the following:
a) High maintenance cost of the Lathe machine.
b) Poor surface finish of the work pieces.
c) Short tool life.
d) Low production rate.
e) Material waste.
f) Increase production cost.
1.3 SCOPE OF STUDY
In order to achieve the objectives of this project, the scopes are as below:
a) Literature review, all information about the Lathe Machine, Tool bits,
the three chosen materials, turning process, surface roughness are
gathered from the Internet.
b) Usage of Lathe machine.
c) Calculation to find out the cutting speed and RPM.
d) Usage of Perthometer.
e) Calculation for surface roughness.
1.4 OBJECTIVE
To determine the Lathe Machine optimum cutting speed for the three chosen
materials (Aluminum, Mild steel and Brass).
The effects are to:
a) reduce the maintenance cost of the Lathe Machine.
b) speed up the work processes
c) reduce down time.
d) increase tool life.
4
CHAPTER 2
LITERATURE REVIEW
2.1 INTRODUCTION
A literature review is a body of text that aims to review the critical points of
current knowledge on a particular research. In this study, the literature review will
focus on the information of the machine used, the processes of the experiment,
surface roughness and all information relevant to the project.
2.2 LATHE MACHINE

Figure 2.1 .Important parts for lathe machine.
5
2.2.1 Description
The purpose of a lathe is to rotate a part against a tool whose position it
controls. It is useful for fabricating parts and/or features that have a circular cross
section. The spindle is the part of the lathe that rotates. Various workholding
attachments such as three jaw chucks, collets, and centers can be held in the spindle.
The spindle is driven by an electric motor through a system of belt drives and/or gear
trains. Spindle speed is controlled by varying the geometry of the drive train.
The tailstock can be used to support the end of the workpiece with a center, or to
hold tools for drilling, reaming, threading, or cutting tapers. It can be adjusted in
position along the ways to accommodate different length workpieces. The ram can be
fed along the axis of rotation with the tailstock handwheel. [6]
The carriage controls and supports the cutting tool. It consists of:
A saddle that mates with and slides along the ways.
An apron that controls the feed mechanisms.
A cross slide that controls transverse motion of the tool (toward or away from the
operator).
A tool compound that adjusts to permit angular tool movement.
A toolpost T-slot that holds the toolpost.
2.2.2 Choosing a Cutting Tool
Cutting tool geometry varies with the type of work to be done. Facing tools
are ground to provide clearance with a center. Roughing tools have a small side
relief angle to leave more material to support the cutting edge during deep cuts.
Finishing tools have a more rounded nose to provide a finer finish. Round nose tools
are for lighter turning. They have no back or side rake to permit cutting in either
direction. Left hand cutting tools are designed to cut best when traveling from left
to right. Aluminum is cut best by specially shaped cutting tools (not shown) that are
used with the cutting edge slightly above center to reduce chatter. [6]
6
2.3 TURNING PROCESS
The lathe can be used to reduce the diameter of a part to a desired dimension.
First, clamp the part securely in a lathe chuck. The part should not extend more that
three times its diameter. Then install a roughing or finishing tool (whichever is
appropriate). If you're feeding the saddle toward the headstock (as in the clip below)
use a right-hand turning tool. Move the tool off the part by backing the carriage up
with the carriage handwheel, and then use the cross feed to set the desired depth of
cut. In the clip below, a finish cut is made using the power feed for a smoother finish.
[6]
2.3.1 Turning Speeds & Feeds
The RPM setting depends on the cutting speed and the diameter of the part.
The RPM setting will change with the diameter of the part. As the diameter of the
part gets smaller, the RPM must increase to maintain the recommended surface
footage. Again, take the case of the wheel. Think of the part as a wheel and the
cutting speed as a distance. A larger wheel (part) will need to turn fewer revolutions
per minute to cover the same distance in the same amount of time than a smaller
wheel (part). Therefore, to maintain the recommended cutting speed, larger diameter
parts must be run at slower speeds than a smaller diameter part. [7]
The lathe must be set so that the part will be operating at the proper surface
speed. Spindle speed settings on the lathe are done in RPMs. To calculate the proper
RPM for the tool and the workpiece, we must use the following formula:
RPM = Cutting speed (mm/min) / . Diameter of work piece (mm)
If two round pieces of different sizes are turning at the same revolutions per
minute (RPM), the larger piece has a greater surface speed. Surface speed is
measured in surface feet per minute (SFPM). All cutting speeds work on the surface
7
footage principle. Again, cutting speeds depend primarily on the kind of material you
are cutting and the kind of cutting tool you are using. The hardness of the work
material has a great deal to do with the recommended cutting speed. The harder the
work material, the slower the cutting speed. The softer the work material, the faster
the recommended cutting speed (Figure 2).[7]
[7]
Figure 2.2: Relationship between cutting speed and material with different hardness
The hardness of the cutting tool material has a great deal to do with the
recommended cutting speed. The harder the cutting tool material, the faster the
cutting speed (figure 3). The softer the cutting tool material, the slower the
recommended cutting speed. [8]
[7]
Figure 2.3 : Relationship between cutting speed and different tool bit used.
2.3.2 Summary of Turning Parameters and Formulae
Cutting feed - The distance that the cutting tool or workpiece advances during
one revolution of the spindle, measured in inches per revolution . In some operations
the tool feeds into the workpiece and in others the workpiece feeds into the tool. For
8
a multi-point tool, the cutting feed is also equal to the feed per tooth, measured in
inches per tooth, multiplied by the number of teeth on the cutting tool.
Cutting speed - The speed of the workpiece surface relative to the edge of the
cutting tool during a cut, measured in surface feet per minute.
Spindle speed - The rotational speed of the spindle and the workpiece in
revolutions per minute (RPM). The spindle speed is equal to the cutting speed divided
by the circumference of the workpiece where the cut is being made. In order to
maintain a constant cutting speed, the spindle speed must vary based on the diameter
of the cut. If the spindle speed is held constant, then the cutting speed will vary.
Feed rate - The speed of the cutting tool's movement relative to the workpiece
as the tool makes a cut. The feed rate is measured in inches per minute and is the
product of the cutting feed (IPR) and the spindle speed (RPM).
Axial depth of cut - The depth of the tool along the axis of the workpiece as it
makes a cut, as in a facing operation. A large axial depth of cut will require a low
feed rate, or else it will result in a high load on the tool and reduce the tool life.
Therefore, a feature is typically machined in several passes as the tool moves to the
specified axial depth of cut for each pass.
N = Rotational speed of the workpiece, rpm
f = Feed, mm/rev or in/rev
v = Feed rate, or linear speed of the tool along workpiece length, mm/min or
in/min
=fN
V = Surface speed of workpiece, m/min or ft/min
= Do N (for maximum speed)
9
= Davg N (for average speed)
l = Length of cut, mm or in.
Do = Original diameter of workpiece, mm or in.
Df = Final diameter of workpiece, mm or in.
Davg = Average diameter of workpiece, mm or in
. = (Do + Df) /2
d = Depth of cut, mm or in.
= (Do - Df) /2
t = Cutting time, s or min
=l/f N
MRR = mm/min or in/mm
= Davg d fN
Torque = Nm or lb ft
= ( Fc )( Davg /2 )
Power = kW or hp
= (Specific energy) (MRR) = (Torque) (w), where w =2 N radians/min [9]
2.4 FACING PROCESS
Reduction in length of the work piece is called facing operation. A lathe can
be used to create a smooth, flat, face very accurately perpendicular to the axis of a
cylindrical part. A single-point turning tool moves radically, along the end of the
10
workpiece, removing a thin layer of material to provide a smooth flat surface. The
depth of the face, typically very small, may be machined in a single pass or may be
reached by machining at a smaller axial depth of cut and making multiple passes.
2.5 BASICS OF METAL CUTTING
Various machine tools and cutting tools are used in metal cutting. Cutting
tools for turning can generally be divided into two groups: high speed steels and
cemented carbides. High speed steel (HSS) cutting tools can be subdivided into three
groups according to their manufacture: single, brazed and indexable inserts.[8]
Cutting tool geometry, chip geometry, cutting speed, cutting tool and workpiece
material, cutting speed and cutting fluid are the main factors affecting the metal
cutting process and[8].
Tool geometry, one of the most important factor affecting metal cutting
process, is determined by rake angle, side clearance angle, side cutting edge angle
and back rake angle. Tool geometry is an important factor having influence on
cutting forces and tool life.[8] For an optimum turning operation, correct selection of
cutting parameters as well as the length of tool holder extending from its post are
essential . That is because, incorrect selection of cutting parameters leads to rapid
tool wear, breakage and plastic deformation. This increases machine tool idle time
due to the changing of damaged cutting tools and causes some other problems such
as poor surface quality and wrong workpiece dimensions. This, in turn, increases the
overall cost. [8]
Determination of cutting parameters through conventional methods is mostly
not possible. Therefore, the use of high capacity computers is also gaining
importance as it is possible to find appropriate solutions for metal cutting operation.
Approximate solution methods giving very close results to those obtained by the
experimental work are appealing as they are easy to use and there is no necessity to
carry out costly experimental work .[8] Parallel to the development in the computer
11
technology, finite element analysis (FEM) method, one of the approximate solution
methods, has been increasingly used. Finite element method gives very close results
to the real values and, therefore, it is now a well accepted numerical method. [8]
2.5.1 Cutting process
Metal cutting is a complex physical phenomenon which involves elastic and
plastic deformation, intense friction and heat, chip formation and cutting tool wear.
In order to effect cutting action, the cutting tool is forced against the workpiece and
is moved relative to the workpiece.[2] As the result, the workpiece is initially
deformed elastically and when the workpieces yield strength is exceeded plastic
deformation occurs. Plastic deformation leads to chip formation The formed chip
leaves the workpiece through the cutting tool rake face. The flow of the chip occurs
in various ways depending on the workpiece properties and cutting conditions . [8]
Figure 2.4. Chip formation process [8]
2.5.2 Cutting forces
The necessary chip formation force required to overcome the developed
stresses during chip formation process can be divided into three components: cutting
force, feed force and radial force . Cutting forces developed during turning are
depicted in