Manufacturing Laboratory-I (ME207) Report

Date of Submission: - 12 - 10 – 2022 Name: - Ankur Bharali

Group: - Monday Entry Number: - 2020MEB1267

(1) EXPERIMENT TITILE: Cutting Force Measurement on Lathe machine

(2) OBJECTIVES:

1) Measurements of cutting forces and calculation of power consumption

during turning operation.
2) To know the working of Dynamometer.

(3) MATERIAL AND APPARATUS USE:

1) Mild steel and Aluminum Rod

2) Lathe Machine
3) Turning tool
4) Dynamometer
5) Charge amplifier, Data acquisition card, Computer.

(4) EXPERIMENTAL PROCEDURE:

1) Insert a mild steel rod into the lathe's three-jaw chuck.

2) Connect the data acquisition card, computer, charge amplifier, carbide tool,
and tool-post to the dynamometer.

3) We first enter the following values into the computer: Speed=420 rpm, Feed
rate=0.04mm/rev, and Depth of cut=0.2 mm for our initial reading.

4) Adjust the speed, feed rate, and cut depth appropriately, then collect a total of
15 readings and save them.

5) Take the aluminum rod in your hands and remove the mild steel rod.

6) Repeat the procedure using an aluminum rod now.

(5) OBSERVATIONS AND CALCULATIONS:

1) Cutting Power Pc = Fc*Vc

(Where Fc= Cutting Force and Vc= Cutting Velocity)

 2) Cutting Velocity Vc = (π*D*N) / 60

(Where D=Work piece Diameter and N= Speed in RPM)

For Aluminum Rod:

RPM DOC FR Fx_mean Fy_mean Fz_mean dia Fc Ft Vc P

420 0.2 0.04 5.195 25.912 21.59 23.9 21.59 26.42763 0.525588 11.34745
420 0.6 0.04 20.001 45.352 49.172 22.7 49.172 49.56656 0.499199 24.54662
420 1 0.04 11.446 25.166 19.391 20.7 19.391 27.64667 0.455217 8.827108
420 0.2 0.05 7.791 29.573 22.175 20.3 22.175 30.58205 0.44642 9.899371
420 0.2 0.06 9.26 26.679 21.772 19.9 21.772 28.24034 0.437624 9.527947
715 0.2 0.04 8.34 36.98 24.733 19.5 24.733 37.90879 0.730028 18.05577
715 0.6 0.04 32.106 62.171 59.249 18.3 59.249 69.97163 0.685103 40.59166
715 1 0.04 47.78 86.984 91.993 16.3 91.993 99.24286 0.610228 56.13672
715 0.2 0.05 11.097 29.534 24.74 15.9 24.74 31.54997 0.595253 14.72657
715 0.2 0.06 8.113 30.798 24.398 15.5 24.398 31.84867 0.580278 14.15763
930 0.2 0.04 8.77 28.3694 22.695 15.1 22.695 29.69404 0.73529 16.6874
930 0.6 0.04 27.443 69.815 63.996 13.9 63.996 75.01501 0.676856 43.31609
930 1 0.04 45.919 82.378 87.797 11.9 87.797 94.31166 0.579467 50.87544
930 0.2 0.05 11.405 34.869 28.974 11.5 28.974 36.6868 0.559989 16.22512
930 0.2 0.06 12.186 37.993 28.771 11.1 28.771 39.89946 0.540511 15.55104

For Mild Steel Rod:

420 0.2 0.04 9.801 20.779 26.747 23.9 26.747 22.97447 0.525588 14.05791
420 0.6 0.04 20.655 42.516 57.854 22.7 57.854 47.26774 0.499199 28.88066
420 1 0.04 29.071 40.62 74.76 20.7 74.76 49.95105 0.455217 34.03201
420 0.2 0.05 4.119 11.631 17.133 20.3 17.133 12.33881 0.44642 7.648519
420 0.2 0.06 3.424 16.158 18.138 19.9 18.138 16.5168 0.437624 7.937622
715 0.2 0.04 7.616 16.868 21.865 19.5 21.865 18.50764 0.730028 15.96205
715 0.6 0.04 26.003 44.426 58.105 18.3 58.105 51.47646 0.685103 39.8079
715 1 0.04 25.255 37.358 70.759 16.3 70.759 45.09363 0.610228 43.17914
715 0.2 0.05 7.308 8.277 18.108 15.9 18.108 11.04154 0.595253 10.77885
715 0.2 0.06 7.442 14.015 19.735 15.5 19.735 15.86832 0.580278 11.45179
930 0.2 0.04 6.208 12.413 15.356 15.1 15.356 13.87883 0.73529 11.29111
930 0.6 0.04 12.992 23.554 37.073 13.9 37.073 26.8995 0.676856 25.09309
930 1 0.04 25.412 47.759 75.075 11.9 75.075 54.09891 0.579467 43.50347
930 0.2 0.05 4.651 15.044 18.693 11.5 18.693 15.74655 0.559989 10.46787
930 0.2 0.06 13.872 15.064 22.789 11.1 22.789 20.4782 0.540511 12.31771
(6) RESULTS AND DISCUSSION :
1) First, we need a rod with a diameter of 23.6 mm made of mild steel.
2) Diameter decreased after each cut to equal the previous diameter less the depth
of cut.
3) Increasing the cut depth causes the cutting force and feed force to rise.
4) As feedrate rises, cutting pressures increase.
5) The best method for measuring force is to use a dynamometer to measure
cutting force.

GRAPH: POWER V/S SPEED

Power vs RPM
20
18
16
14
Power (watt)

12
10
Al
8
6 MS
4
2
0
0 200 400 600 800 1000
RPM

GRAPH: POWER Vs DEPTH OF CUT

Power vs Depth of Cut

40
35
30
Power (watt)

25
20
Al
15
MS
10
5
0
0 0.2 0.4 0.6 0.8 1 1.2
Depth of Cut (mm)
GRAPH: POWER Vs FEED RATE
Power vs Feed Rate
16
14
12
Power (watt)

10
8
Series1
6
MS
4
2
0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07
Feed Rate (mm/rev.)

(7) LEARNING FROM THE EXPERIMENT:

1) The merchant circle diagram and its uses were covered.

2) We learned about utilizing a computer to gather data during turning

operations.

3) I learned a little bit about how a dynamometer works.

4) A greater understanding of turning processes and lathe machines.

5) We mastered the art of manually setting the necessary spindle speed.

(8) SAFETY CONCERN:

1) Refrain from putting your hands or fingers near any moving parts or cutting
equipment.

2) Never stop a moving chuck with your hand.

3) Avoid donning loose garments, jewelry, watches, or gloves.

4) Avoid touching any exposed electrical connections or wires.

5) Lab coats and eye protection should always be used when utilizing workshop
equipment