Manufacturing Laboratory-I (ME207) Report

Date of submission: 10/02/2021 Name: Ashutosh Garg

Group: G7 Entry No: 2018MEB1213

Experiment No. 4

Experiment title: Measurement of cutting forces and power required for turning operation
and compare with analytical results.

Objectives:

The main objectives of the Experiment is:

1. To measure the cutting forces.
2. To calculate the errors in Shear Strength from the standard value of 370 MPa in
case of mild steel (Comparing the analytical results with actual results.).
3. Calculating Power consumptions in turning operations.

Material and apparatus used:

1. Multi-Coated Carbide Tool.

2. Charge Amplifier
3. Force Dynamometer (Kistler 9257B)
4. Workpiece (Cylinderical Rod)
5. Lathe Machine
6. Desktop having suitable softwares and hardwares for load measurements.

Experimental procedure:

1. Turn on the Lathe Machine and clamp the Mild steel Workpiece on the three jaw
chuck properly and carefully and perform the initial facing.
2. Now we need to handle three type of cases:
a. Varying Rpm.
b. Varying Feed
c. Varying Depth of cut.
3. In Varying Rpm, Feed and Depth of Cut is fixed as 0.04 mm/rev and 0.4 mm
respectively and the Spindle Speed is changed and set to:
i. 550 Rpm
ii. 775 Rpm
iii. 930 Rpm
 4. In varying Feed, the Spindle Speed and Depth of cut is set to 550 Rpm and 0.4
mm respectively, and the feed is set as folloed for various cases:
i. 0.04 mm/rev
ii. 0.08 mm/rev
iii. 0.16 mm/rev
5. In varying Depth of cut, the Spindle speed and Feed is set to 550 Rpm and 0.04
mm/rev and depth of cut us set as follows for different cases:
i. 0.2 mm
ii. 0.4 mm
iii. 0.6 mm
6. Readings were taken and other analytical results were also calculated and
compared.
7. Readings of Feed forces, Radial forces and Cutting forces are measured and
collected using dynamometer.

Results and Discussion:

Feed
Spindle Depth Radial Cutting Shear Shear
Feed force, % Power
SNo. Parameters speed of cut force, force, force, strength
(mm/rev) Fx error (W)
(Rpm) (mm) Fy (N) Fz (N) Fs (N) (MPa)
(N)
1. Varying Rpm 550 0.04 0.4 8.56 1.82 21.02 12.63 438.05 18.392 15.13
2. Varying Rpm 775 0.04 0.4 7.23 1.22 19.29 11.72 415.76 12.367 19.57
3. Varying Rpm 930 0.04 0.4 5.41 0.6 16.77 10.37 380.88 2.9399 20.42
4. Varying Feed 550 0.04 0.4 8.56 1.82 21.02 12.63 438.05 18.392 15.13
5. Varying Feed 550 0.08 0.4 9.87 2.38 35.12 21.97 412.58 11.509 25.28
6. Varying Feed 550 0.16 0.4 10.32 4.24 57.92 37.56 373.65 0.9876 41.70
Varying Depth
7. 550 0.04 0.2 4.34 0.69 10.45 6.27 433.87 17.262 7.52
of Cut
Varying Depth
8. 550 0.04 0.4 8.56 1.82 21.02 12.63 438.05 18.392 15.13
of Cut
Varying Depth
9. 550 0.04 0.6 9.92 2.84 28.44 17.37 415.32 12.249 20.48
of Cut

Note: The other Calculations are not mntioned here but The Fourth page (Not part of the
report) Contains the other values(Not according to the proper mentioned units).

It is clearly observable that the error in the Analytical and the theoritical value of 370 MPa
of the Shear Strength is considerabily large and even reaches near to 18% which is huge
error. Let’s now check the possible reasons for the same:
a. As we have used the merchant relations for the entire basis of calculations
and as we are clearly aware that the merchant equations are based on
some certain assumptions and hence there is a huge chance of errors.
b. Some of the possible assumptions that are causing the difference are as
follows:
 i. Merchant equation consider the cutting tool as a single point contact
tool which cannot be the situation when working in a real scenerio.
ii. Force equilibrum is hard to maintain in all the firections while
performing the experiments.
iii. The merchant equation assumes that the tool will cut the workpiece
othogonally which is hard to maintain and check in real working
scenerio.

Learnings from the Experiment:

 I learnt to use the merchant equation and merchant circle diagram properly.
 I also learnt about the various parts and their fuctions that the Lathe Machine
contains.
 The major learning lied in the comparison and analysis of the errors and results.

---END---
 This is not a part of report but just an extra calculation part which was used to reach to
the final results mentioned in the report.

Feed
Alpha(In r (nose Coefficient
Fc Ft Phi F N Beta As Rate in Vc
radians) radius) of friction
mm/min

21.02 8.751342754 0.209 0.588144306 0.8 12.93041 18.74116 0.6899 0.603947 0.028838 22.00 719.9483
19.29 7.332209762 0.209 0.60377914 0.8 11.1826 17.34402 0.6448 0.572678 0.028181 31.00 1014.473
16.77 5.443170032 0.209 0.628473161 0.8 8.810903 15.27184 0.5769 0.52329 0.027215 37.20 1217.367
21.02 8.751342754 0.209 0.588144306 0.8 12.93041 18.74116 0.6899 0.603947 0.028838 22.00 719.9483
35.12 10.15289614 0.209 0.64468853 0.8 17.23289 32.24164 0.5345 0.490859 0.053249 44.00 719.9483
57.92 11.15706054 0.209 0.690249197 0.8 22.9555 54.33463 0.4225 0.399737 0.100514 88.00 719.9483
10.45 4.394507936 0.209 0.586360189 0.8 6.471155 9.307973 0.6952 0.607515 0.014458 22.00 719.9483
21.02 8.751342754 0.209 0.588144306 0.8 12.93041 18.74116 0.6899 0.603947 0.028838 22.00 719.9483
28.44 10.31852703 0.209 0.611374413 0.8 16.00605 25.67318 0.6235 0.557487 0.041812 22.00 719.9483