Determination of cutting forces during

longitudinal and transverse turning processes

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Pilani Campus
Theory of Turning process

• Turning is a machining process in which a cutting tool, describes a helix toolpath by moving linearly while the workpiece
rotates

• Three common turning operations:

• Longitudinal turning

• Facing/ transverse turning

• Profiling

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Definitions of terms

1. Spindle speed: The spindle speed rpm (revolution

per minute) is the rotation of the chuck and
workpiece.

2. Cutting speed
The cutting speed is the surface/peripheral speed,
m/min (ft/min), at which the tool moves along the
workpiece in feet (meters) per minute.

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Definition of cutting speed

π
The definition of cutting speed (vc) as the result of the diameter, pi ( ) and the spindle speed (n) in the
revolutions per minute (rpm). The circumference (C) is the distance the cutting edge moves in a revolution.

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Theory of Turning process

3. Feed: The cutting feed (fn) in mm/r (inch/r) is the movement of the tool in relation to the revolving workpiece.

4. Depth of cut:- The cutting depth (ap) in mm (inch) is half of the difference between the un-cut and cut diameter of the
workpiece. The cutting depth is always measured at right angles to the feed direction of the tool.

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Effects of cutting speed
The single largest factor determining tool life

Effects of feed rate

The single largest factor determining productivity

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Effects of depth of cut
The single largest factor determining high power consumption

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Theory of Turning process

Figure 1. Forces acting on the Chip during orthogonal cutting Figure 2. Measurable forces acting on the tool

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Theory of Turning process

• Figure 1 shows the forces acting on a chip during orthogonal cutting. The tool exerts a force (R) on the chip which can be
separated into two mutually perpendicular components: friction force (F) and normal force to friction (N). These two
components can be used to define the coefficient of friction between the tool and the chip (β).
• The workpiece applies a force (R΄) on the chip which has two components: shear force (Fs) and normal force to shear (Fn).
In equilibrium condition, the forces acting on the chip must be in balance i.e. R and R΄ must be equal in magnitude,
opposite in direction, and collinear. None of the four force components F, N, Fs, and Fn can be directly measured in a
machining operation due to variation in their application directions with change in tool geometry and cutting conditions.

• Therefore, the cutting tool is instrumented using a force measuring device called a dynamometer to record the force
components which act against the tool: cutting force (Fc: in the direction of cutting) and thrust force (Ft: perpendicular to
the cutting force). The cutting force and thrust force are shown in Figure 2 together with their resultant force R΄΄.

• The force transducers in the dynamometer can be aligned to match the respective known directions of Fc and Ft. In the
present experiment, Fc and Ft will be measured during longitudinal and transverse turning process.

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Practical Demonstration

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Procedure

1. Hold the Aluminum work piece in lathe chuck.

2. Set the dynamometer in place of tool post and hold the right-hand turning tool in dynamometer.
3. Set all attachments with dynamometer and switch on the machine for readings.
4. Set spindle speed and feed rate from respective handles.
5. Perform the longitudinal turning on aluminum work piece.
6. Use the combination of parameters shown in the below table for performing the experiments.

Spindle 375 ( R) 600 (S) 940 (T)

Speed
(RPM)
Depth 0.5 1.0 1.5 0.5 1.0 1.5 0.5 1.0 1.5
Cut
(mm)
Feed 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Rate
(Mm/R 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7
ev.) 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9

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7. Record the force values through the dynamometer.
8. Now perform the experiment following the combination of parameters presented in the below table and record
the values of forces using the dynamometer.
Spindle 60 ( R) 96 (S) 150 (T)
Speed
(RPM)
Depth 0.5 1.0 1.5 0.5 1.0 1.5 0.5 1.0 1.5
Cut
(mm)
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Feed 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7
Rate
0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9
(Mm/Re
v.)

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9. Repeat the experiments using the below combination of parameters and record the force values.
Spindle 375 ( R) 600 (S) 940 (T)
Speed
(RPM)
Depth 0.2 0.4 0.6 0.2 0.4 0.6 0.2 0.4 0.6
Cut
(mm)
0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
Feed 0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.012
Rate 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015
(Mm/Re
v.)

Spindle 60 ( R) 96 (S) 150 (T)

Speed
(RPM)
Depth 0.2 0.4 0.6 0.2 0.4 0.6 0.2 0.4 0.6
Cut
(mm)
0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
Feed 0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.012
Rate
0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015
(Mm/Re
v.)

10. Analyze the results

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Quiz Time

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