MF F316 - Machining & Machine tools

Dr. Divyansh Patel

Instructor-in-charge
divyansh.patel@pilani.bits-pilani.ac.in

BITS Pilani Mr. Naveen P. T. Mr. Ayush Owhal

Pilani Campus
Instructors
 MF F316 M&MT
2:00 – 4:00 PM
#Exp_No.
MACHINED SURFACE FINISH AND MEASUREMENTS AND Exp. +
#LAB_1 1 31st Aug.
DEMONSTRATION OF CO-ORDINATE MEASUREMENT MACHINE Demo

DETERMINATION OF CUTTING FORCES DURING LONGITUDINAL AND

#LAB_2 2 7th Sept. Exp.
TRANSVERSE TURNING PROCESSES

ANALYSIS OF TOOL WEAR OF SINGLE POINT AND MULTI POINT

#LAB_3 3 14th Sept. Exp.
CUTTING TOOLS UNDER DIFFERENT MACHINING CONDITIONS

ANALYZING THE CUTTING FORCES IN FACE MILLING PROCESS ON

#LAB_4 4 21st Sept. Exp.
ALUMINIUM & MS BLOCK

TO STUDY GRINDING OF MILD STEEL AND SILVER STEEL AND SURFACE

#LAB_5 5 28th Sept. Exp.
ROUGHNESS PRODUCED AT DIFFERENT GRINDING PARAMETERS

#LAB_6 / 05th Oct. ----------------------------------------- QUIZ ---------------------------------------- /

#LAB_/ / 12th Oct. ----------------------------------- Mid Sem Exam ----------------------------------- /

2 Department of Mechanical Engineering, BITS Pilani

 MF F316 M&MT
2:00 – 4:00 PM
#Exp_No.

#LAB_7 DEMONSTRATION OF LATH GEAR BOX, REGULATION OF SPEED

6 19th Oct. Demo
AND FEED RATE

#LAB_8 7 26th Oct. DEMONSTRATION OF CNC MACHINING Demo

#LAB_/ / 02nd Nov. -------------------- BUFFER LAB OR DIWALI HOLIDAY --------------------- /

Exp. +
#LAB_9 8 09th Nov. ALIGNMENT TESTS FOR MACHINE TOOLS Demo

Demo +
#LAB_10 9 16th Nov. DEMONSTRATION OF JIGS AND FIXTURES + ---------- QUIZ ---------- Quiz

#LAB_/ / 23rd Nov. ----------------------------- BUFFER LAB -------------------------------------- /

3 Department of Mechanical Engineering, BITS Pilani

 MACHINED SURFACE FINISH AND MEASUREMENTS
AND DEMONSTRATION OF CO-ORDINATE
MEASUREMENT MACHINE
#LAB_1
BITS Pilani Presented by: Ayush Owhal
Pilani Campus
Instructor
MACHINED SURFACE FINISH AND MEASUREMENTS AND DEMONSTRATION
OF CO-ORDINATE MEASUREMENT MACHINE

Experiment No. 1

• To perform measurement of surface roughness of machined rods of different materials

Objective
• To understand the working of Co-ordinate Measurement Machine (CMM)

Equipment
• Surface roughness tester and CMM
required

Sample • Calibration surface, silver-steel and mild-steel machined rods (for surface roughness test)
details • Plastic object with flat and cylindrical surfaces and standard calibration ball (for CMM)

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Need of surface roughness measurement

• Variations in the surface texture can influence a variety of performance characteristics,

here the surface finish can affect the ability of the part

✓ To resist wear and fatigue

✓ To assist or destroy effective lubrication

✓ To increase or decrease friction and/or abrasion with mating parts; and

✓ To resist corrosion

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 Instrument details

Instrument: Surface roughness tester

Make: Mitutoyo, Japan
Model: SJ-410 series
Year: 2020
Vertical adjustment range: 250 mm
Dimensions: 400×250×578 mm
Mass: 20 kg

Fig. 1: Surface roughness tester

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Special features of surface roughness tester

• A spherical or cylindrical surface cannot be evaluated, but, by removing the radius with a filter, roughness
data is processed as if taken from a flat surface. Other curved surfaces can be processed besides
cylindrical, such as parabolical and ellipsoidal.

Fig. 2: Cylindrical Surface

roughness testing

• Supporting not only surface roughness measurement but also fine contour measurement

Fig. 3: Surface roughness

tester

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Standard nomenclatures

Parameter Name Parameter Name

Ra Roughness Average (Ra) S Mean Spacing of Local Peaks

Rq Root Mean Square (RMS) Roughness Sm Mean Spacing of Profile Irregularities
Rt Maximum Height of the Profile D Profile Peak Density
Rv, Rm Maximum Profile Valley Depth Pc Peak Count (Peak Density)
Rp Maximum Profile Peak Height HSC Hight Spot Count
Rpm Average Max. Profile Peak Height la Average Wavelength of the Profile
Rz Average Max. Height of the Profile lq RMS Wavelength of the Profile
Rmax Maximum Roughness Depth Da Average Absolute Slope
Rc Mean Height of Profile Irregularities Dq Root Mean Square (RMS) Slope
Rz(iso) Roughness Height Lo Developed Profile Length
Ry Maximum Height of the Profile lr Profile Length Ratio
Wt, W Waviness Height Rsk Skewness

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Output

Fig. 4: Output Touch display

results

Print output

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Calculation for Ra and Rq

𝑌1 + 𝑌2 + ….+ 𝑌𝑁
𝐹𝑜𝑟 𝑅𝑎 => 𝑅𝑎 =
𝑁
𝑙
The digital approximation is: 𝑅𝑎 = 1/𝐿 ‫׬‬0 𝑌(𝑙) 𝑑𝑙

𝐿 = sample length
𝑌(𝑙) = the profile height function
1/2
𝑌12 + 𝑌22 + ….+𝑌𝑁2
𝐹𝑜𝑟 𝑅𝑞 => 𝑅𝑞 =
𝑁

𝑙 1/2
The digital approximation is: 𝑅𝑞 = 1/𝐿 න 𝑌 𝑙 2 𝑑𝑙
0

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Comparison between Ra and Rq

1 2

Ra1 = Ra2

Rq1 < Rq2

• A single large peak or flaw within the microscopic surface texture will effect (raise) the
RMS value more than the Ra value.

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Test
sample

Sample details:
Material : Silver-steel and Mild-steel rod
Surface type : Machined
Diameter : 25 mm (approx.)
No. of samples surfaces: 3

Fig. 5: Samples

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Practical
videos

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Resul
ts

Rod material Ra values Average Ra Std. Deviation

value
Sample 1 Sample 2 Sample 3

0.951 1.082 1.002

Silver-steel 0.647 0.749 0.965 0.935 0.128

1.437 0.908 0.681

1.293 1.697 0.804

Mild-steel
1.333 2.053 3.843 2.173 0.816

2.582 2.957 2.997

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DEMONSTRATION OF CO-ORDINATE
MEASUREMENT MACHINE

Instrument details
Instrument: CMM
Make: Mitutoyo, Japan
Model: CRYSTA-Apex S/ 574
Year: 2020

Fig. 1: Coordinate measuring machine

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Specifications

Model No. CRYSTA-Apex S574

X axis 19.68" (500mm)
Measuring range Y axis 27.55" (700mm)
Z axis 15.75" (400mm)
Resolution 0.000004" (0.0001mm)
Guide method Air bearings on each axis
Max. moving speed = 519mm/s (20.4"/s) (3D)
CNC mode: Auto
Max. measuring speed = 8mm/s
Drive speed
Max. moving speed = 239mm/s (9.4"/s) (3D)
CNC mode: Manual
Max. measuring speed = 8mm/s
Max. drive acceleration 2,309 mm/s2 (3D)
Maximum height 21.45" (545mm)
Workpiece
Maximum mass 396.8lbs. (180kg)
Mass (including all available accessories ) 1,377lbs. (625kg)
Pressure 58 PSI (0.4MPa)
Air supply Consumption 1.76CFM (50L/min) under normal conditions
Air source 3.53CFM (100L/min)
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Need of surface roughness measurement

• A coordinate measuring machine, also known as a CMM, is a piece of equipment that

measures the geometries of physical objects. CMMs using a probing system to detect
discreet points on the surfaces of objects.
✓ CMM uses a 3D tracing device with a simple digital readout that displayed XYZ
positions and gives the information about geometry of the part.
✓ To determine whether or not it respects the original design intent.
✓ CMMs are integrated within quality assurance or quality control workflows to check
the dimensions of manufactured components to prevent or resolve quality issues.
✓ To reduce chances of human error during manual inspections or checks performed
with conventional metrology instruments.
✓ Reverse engineering.

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Special features

High accuracy in the 1.7 μm class

• The CRYSTA-Apex S is a high-accuracy CNC coordinate measuring machine that

guarantees a maximum permissible error of *E0,MPE = (1.7+3L/1000)μm [500
Series].

• The measuring machine uncertainty is not more than one-fifth (ideally one-tenth).

• The higher accuracy specification of the CRYSTA-Apex S, therefore, gives it more

than double the effective measuring range in terms of accuracy-guarantee
capability in this case.*ISO 10360-2:2009

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Special features

Temperature compensation system

• The CRYSTA-Apex S comes equipped with a temperature compensation system
that guarantees the accuracy of measurement under temperature conditions of
60.8 to 78.8 °F (16 to 26 °C).

• From sensors installed on each axis scale and working in conjunction with
sensors placed on the workpiece, temperatures are obtained before outputting
the measurement result to the controller.

• Thermal compensation is applied based on 68 °F (20 °C), taking into account

the workpiece material expansion coefficient.

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GEOPAK (general-purpose measurement
program) The GEOPAK module is the heart
of the MCOSMOS software system and is
used to measure and analyze geometric
elements.

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CAT1000P (CAD-based programming) This
module enables the user to use CAD data and on-
screen simulation to create parts programs for
making automated measurements.

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CAT1000S (freeform surface
evaluation) Checks and compares the
workpiece with the CAD data containing
freeform surfaces and directly outputs
the results in the form of CAD.

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CRYSTA-Apex S500 Series Installation Temperature

Temperature Temperature
environment 1 environment 2

Temperature
20±2 °C (64.4-71.6 °F) 16 - 26 °C (60.8-78.8 °F)
Range
Limits within
which Rate of 2 °C per hour or less 2 °C 2 °C per hour or less 5 °C
accuracy is change in 24 hours or less in 24 hours or less
guaranteed
Gradient 1 °C or less per meter 1 °C or less per meter

BITS Pilani, Pilani Campus

CRYSTA-Apex S500 Series Accuracy

unit: μm

Maximum permissible
Maximum permissible error (E0,MPE)
Probe used probing error (PFTU,MPE)
ISO 10360-2:2009
ISO 10360-5:2010

SP25M 1.7+3 L/1000 (temperature environment 1)

1.7
(Stylus: ø4 X 50mm) 1.7+4 L/1000 (temperature environment 2)

TP200 1.9+3 L/1000 (temperature environment 1)

1.9
(Stylus: ø4 X 10mm) 1.9+4 L/1000 (temperature environment 2)

TP20 2.2+3 L/1000 (temperature environment 1)

2.2
(Stylus: ø4 X 10mm) 2.2+4 L/1000 (temperature environment 2)

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Practical videos

BITS Pilani, Pilani Campus

Thanks

BITS Pilani, Pilani Campus