Indian Institute of Technology

Kharagpur
Department of Mechanical Engineering

Machining Experiment - 2

MACHINES TOOLS AND MACHINING LAB (ME39604)

Group - D22

Group Members

19MF10043 Soumya Ranjan Mishra

19MF10044 Madeti Karthikeya

19MF3EP05 Rahul Raghunath Bodanki

19MF3EP13 Ritik

19MF3IM01 Aditya Mallick

19MF3IM02 Alampal Singh

19MF3IM03 Aryan Sinha

19MF3IM04 Katravath Vasu

19MF3IM05 Kumar Sambhaw

19MF3IM06 Kalyan Badavath

19MF3IM07 Manonmani Ambati

19MF3IM08 Mriganka Mitra

Aim:

To study the effect of process parameters and cutting environment (without

and with coolant-lubricant) on chip characteristics in turning of medium
carbon steel with uncoated carbide insert.

Instruments and material used:

C60 steel (Work material), grade P30(cutting tool), Mineral oil(coolant)

SPUN carbide inserts.

Theory:

Morphology and mode of chips are quite important indices to judge

machinability characteristics of any work-tool combination under given
machining conditions. All parameters involved in machining play significant
roles on such machinability characteristics.

Formula chip reduction coefficient (ζ) = a1/a2

a1 = s sin(φ)

cos( γ o)
tan(βo) = ζ −sin( γ o)

For our case γo = 6o and φ = 75o

⇒ tan(βo) = cos(6° )
¿¿
1
⇒ βo = tan -1 = (ζ −6 ° )

where βo the shear angle.

 Procedural steps:

I. Measure the workpiece diameter and note down the available speed - feed
combination.
II. Calculate and set appropriate rpm of the spindle using variable spindle drive.
III. Collect chips after a few seconds of machining.
IV. Note the colour and form of the chips.
V. Measure the average thickness( a2 ) of the chips.
VI. Determine the value of chip reduction coefficient ( ζ ) and shear angle( βo ) for all the
machining conditions.

Observation Table:

Rake angle(𝛾0)= 6°, principal cutting edge angle(φ) = 75° Machining

Environment : Dry , Cutting Tool : SPUN

S Rotational VC S a ζ β
. speed of the (mm/ 0(ra Remarks
n spindle(rpm) m/min rev) 2
d)
o (
m
m
)
1 100 60 0.335 2.16 0.4492 Due to the
76
2 136 80 0.361 2.33 0.4193 absence coolant
0.16
58
the chip reduction
3 167 100 0.323 2.09 0.4644
00
coefficien is
4 201 120 0.289 1.87 0.5130
00 having a high
5 0.08 0.180 2.32 0.4204
94 value for lower
6 0.12 0.310 2.67 0.3692
167 100 45 speed but the
7 0.16 0.323 2.09 0.4644 shear angle is
00
8 0.20 0.377 1.95 0.4939 small
15
 Machining Environment : WET , Cutting Tool : SPUN

S Rotational VC S a2 ζ β0(ra
. speed of the (mm/ Remarks
(m/ (m d)
n spindle(rpm) rev)
min) m)
o
1 100 60 0.2 1.90 0.5053 As the effect of the
94 23
2 136 80 0.3 2.02 0.4778 coolant the chip
0.16
13 53
3 167 100 0.2 1.84 0.5194 reduction coefficient
85 41
4 201 120 0.2 1.67 0.5643 is reduced significantly
59 59
5 0.08 0.1 2.04 0.4737 Compared to the dry
58 47
6 0.12 0.2 2.35 0.4161 cutting environment
167 100 73 53
7 0.16 0.2 1.84 0.5194 and increase in shear
85 41
8 0.20 0.3 1.71 0.5522 angle
32 86
Plots

Graph 1
Effects of variation of VC and cutting fluid application on values of ζ and βo

Graph 2
Effects of variation of S and cutting fluid application on values of βo and ζ
Questions and discussions:
1. Discuss the effect of cutting speed and feed on chip form/shape.

Ans: It was observed that at a higher cutting speed more number of continuous chips were formed and it
was decreasing with the decrease in the cutting speed. In the case of ,feed it was observed that at lower feed we
were getting more continuous chips and the number decreased with the increase in the feed rate.

2. Reveal the effects of cutting speed and feed on the ζ and βo for different machining environments.

Ans: The value of chip reduction coefficient ( ζ ) is low for all the velocities in the case of straight turning with
cutting fluid as compared to the case in which cutting fluid was not used. The shear angle( βo ) is more for all the
velocities in the case of straight turning with fluid as compared to the case in which fluid was not used. For all
values of S the chip reduction coefficient ( ζ ) is low for the case of straight turning with cutting fluid as compared to
the case in which fluid is not used. For all values of S the shear angle is more in case of straight turning with cutting
fluid as compared to the case in which fluid was not used.

3. Discuss the effect of process parameters and cutting environment on chip characteristics.

Ans: There was a huge contrast in the color of the chips formed from straight turing with and without cutting
fluid. This can be due to the lubrication in presence of cutting fluid. In general, with the increase in the cutting speed
we were getting chips with lower thickness and similarly with the increase of the speed rate we were getting chips
with lower thickness