International Journal of Application or Innovation in Engineering & Management (IJAIEM) Web Site: www.ijaiem.org Email: [email protected], [email protected] Volume 3, Issue 9, September 2014 ISSN 2319 - 4847

MEASURING CUTTING FORCES WHILE CUTTING OF DIFFERENT METALS WITH DIFFERENT SPEEDS B.TULASIRAMARAO1, Dr.K.SRINIVAS2 ,Dr. P RAM REDDY3, A.RAVEENDRA4, Dr.B.V.R.RAVI KUMAR INDIA 5 1

Asst. prof, Dept of Mech Engg, Malla Reddy Istitute of Engineering &Technology, Secunderabad AP, INDIA 2Professor, Dept of Mech Engg, RVR&JC college of Engineering, Guntur, AP, INDIA 3

Professor ,Dept of Mech Engg , Dean Academics, Malla Reddy College Of Engineering & Technology. Secunderabad , AP, INDIA 4

Assoc. professor, Dept of Mech Engg, Malla Reddy Engineering Coolege, Secunderabad AP, INDIA 5

Professor, Dept of Mech Engg, VNRVJIET, Hyderabad, AP, INDIA

ABSTRACT In this study, a lathe tool dynamometer that can measure cutting force, feed force and also thrust/Axial force by using strain gauge accelerometer has been Studied and used. The dynamometer used in this project is a 500kg force 3-component system. The dynamometer is connected to a data acquisition system. As the tool comes in contact with the work piece the various forces developed are captured and transformed into numerical form system. In this project various forces for three different materials have been noted down and the materials used in this project are aluminum, brass and mid steel. The forces on these materials with variation in speed are studied. Graphs are drawn on how these forces vary due to variation in speed.

Keywords: Cutting speed, depth of cut and cutting force

1. INTRODUCTION In the metal working industry work pieces of most different shapes and dimensions and different materials are worked. The various working processes fall into two groups. The groups are: 1. Non – cutting shaping process 2. Cutting shaping process  Non – cutting shaping process: In this process no chip formation takes place and the metal is shaped under the action of heat, pressure or both. Example: Forging, drawing, spinning, rolling, extrusion etc.  Cutting shaping process: In this process the finished surface f desired shape and dimensions is obtained by separating a layer from the parent work piece in the form of chips. Example: turning, drilling, milling, shaping, planning etc. The ever increasing importance of machining operation is gaining new dimensions in the present industrial age, in which the growing competition calls for all the efforts to be directed towards the economical manufacture of machined parts. In this context, it is obviously of a vital important to understand and practice the principles of metal machining very thoroughly in order to achieve the following basic objectives of efficient and economical machining practice. 1. Quick metal removal 2. High class surface finish 3. Economy in tool cost 4. Less power consumption 5. Minimum idle time of machine tools 6. Economy in the cost of replacement and sharpening of tools. 1.1 MECHANISM OF METAL CUTTING: The metal cutting is done by a relative motion between the work piece and the hard edge of a cutting tool. Metal cutting could be done either by a single point cutting tool or a multipoint cutting tool. There are two basic types of metal cutting by a single point cutting tool. They are orthogonal and oblique metal cutting. If the cutting edge of the tool is at 90o to the direction of the tool travel, then the cutting action is called as orthogonal cutting. If the cutting face of the tool is inclined at less than 90o to the path of the tool then the cutting action is called as oblique cutting In the manufacturing of various machine components, a number of machining

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International Journal of Application or Innovation in Engineering & Management (IJAIEM) Web Site: www.ijaiem.org Email: [email protected], [email protected] Volume 3, Issue 9, September 2014 ISSN 2319 - 4847 operations are carried out. Hence, it is essential to study the metal cutting process for economical aspects. To investigate the performance of cutting tools during metal cutting, the measurement of cutting forces is essential.

2. OPERATING PROCEDURE The work piece is held in the chuck and facing operation is performed to make the end face of the work piece flat.

Figure 1: facing operation  The work piece is centre drilled to provide tapered hole which can then accommodate and be supported by a running centre in the tail stock.  Undercutting operation is done to provide a groove on the work piece in order to have a reference point  Place the sensing unit of the dynamometer on lathe tool post and clamp rigidly.  With the help of cable provided, carefully connect cable on sensing unit to socket on back plate of Force Indicator Unit.  Connect Force Indicator to 230 V, single phase supply and switch ‘ON’ supply.  Wait for 5 to 10 minutes and then balance the channels to get zero readings on display with tare pots on the panel.  Mount solid work – piece in the chuck.  Wait to stabilize the output of the bridges and measure the maximum output for thrust, feed & radial forces.  The Vertical, Horizontal & radial forces on the dynamometer should not exceed the limit 300 kg. ( For safety purpose work up to 200 Kg )  Note down the reading and repeat the same procedure for various speeds. 2.1 MATERIALS USED FOR TESTING 1. Aluminum 2. Brass 3. Mild steel

3.LIST OF TABULAR COLUMNS AND GRAPHS 3.1 FORCE VS SPEED (ALUMINIUM) Depth of cut: 0.30 mm

Material: Aluminium

Graph: 1

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International Journal of Application or Innovation in Engineering & Management (IJAIEM) Web Site: www.ijaiem.org Email: [email protected], [email protected] Volume 3, Issue 9, September 2014 ISSN 2319 - 4847 Tab: 1 speed 400 630 1000

Cutting force(Ft) 2 4 3

Feed force(Ff) 1 1 1

Depth of cut: 0.60 mm

Thrust force(Ft) 1 3 4

Material: Aluminium

Graph: 2 Tab: 2 Speed 400 630 1000

Cutting force(Fc) 3 6 5

Feed force(Ff) 2 3 3

Depth of cut: 0.90 mm

Thrust force(Ft) 3 4 4 Material: Aluminium

Fig: 3 Tab: 3 Speed 400 630 1000

Cutting force(Fc) 5 7 6

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Feed force(Ff) 3 4 4

Thrust force(Ft) 4 5 4

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International Journal of Application or Innovation in Engineering & Management (IJAIEM) Web Site: www.ijaiem.org Email: [email protected], [email protected] Volume 3, Issue 9, September 2014 ISSN 2319 - 4847 3.2 FORCE VS SPEED (BRASS) Depth of cut: 0.30 mm

Material: Brass

Fig: 4 Tab: 4 Speed 400 430 1000

Cutting force(Fc) 2 7 1

Feed force(Ff) 1 1 1

Depth of cut: 0.60 mm

Thrust force(Ft) 4 6 1 Material: Brass

Fig: 5 Tab: 5 Speed 400 630 1000

Cutting force(Fc) 3 6 3

Feed force(Ff) 2 4 3

Depth of cut: 0.90 mm

Thrust force(Ft) 5 5 3 Material: Brass

Fig : 6

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International Journal of Application or Innovation in Engineering & Management (IJAIEM) Web Site: www.ijaiem.org Email: [email protected], [email protected] Volume 3, Issue 9, September 2014 ISSN 2319 - 4847 Tab: 6 Speed 400 630 1000

Cutting force(Fc) 2 5 4

Feed force(Ff) 1 3 4

Thrust force(Ft) 4 4 4

3.3 FORCE VS SPEED (MILD STEEL) Depth of cut: 0.30 mm

Material: Mild steel

Fig: 7 Tab: 7 Speed 400 630 1000

Cutting force(Fc) 3 5 3

Feed force(Ff) 2 2 2

Depth of cut: 0.60 mm

Thrust force(Ft) 4 3 4

Material: Mild Steel

Fig :8 Tab: 8 Speed

Cutting force(Fc)

Feed force(Ff)

Thrust force(Ft)

400

7

3

5

630

8

3

6

1000

6

3

5

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International Journal of Application or Innovation in Engineering & Management (IJAIEM) Web Site: www.ijaiem.org Email: [email protected], [email protected] Volume 3, Issue 9, September 2014 ISSN 2319 - 4847 Depth of cut: 0.90 mm

Material: Mild Steel

Force Vs Speed 15 Force 10 (kgf) 5

Cutting Force (Fc) Feed Force (Fc)

0 400

630

1000

Axial Force (Ft)

Speed (rpm)

Fig: 9 Tab: 9 Speed 400 630 1000

Cutting force(Fc) 9 10 8

Feed force(Ff) 5 5 5

Thrust force(Ft) 4 4 7

4.RESULT & CONCLUSION In this project the various forces such as cutting force, feed force and the axial force have been found out with the variation in speed for different materials like aluminum, brass and mild steel. Graphs are drawn on how these forces vary with the variation in the speed. From the graphs it has been observed that as the speed increases, the forces also increase up to certain limit and then decreases with any further increase in speed i.e., forces developed at 630 rpm are higher compared to 400 rpm and 1000 rpm And in this project we have studied how a dynamometer works, learnt about various elements involved in metal cutting process. For the further enhancement of this project a thermocouple if connected can be used to find the temperature developed during the machining process.

REFERENCES [1] Oktem. H., Erzurumlu. T., Kurtaran. H., 2005. Application of response surface methodology in the optimization of cutting conditions for surface roughness. J. Mater. Process. Technol. Vol.170, pp. 11–16 [2] Abouelatta. O.B. and Madi. J“ Surface roughness prediction based on cutting parameters and tool vibration in turning operations”, Journal of Materials Processing Technology, 118, 2001, pp.269-277. [3] W. E. Biles, James J. Swain, “Optimization and industrial experimentation”, 1980, John Wiley & sons, New York. [4] Muammer Nalbant, Hasan Gokkaya, and Ihsan Toktas¸2007. Comparison of Regression and Artificial Neural Network Models for Surface Roughness Prediction with the Cutting Parameters in CNC Turning. Modelling and Simulation in Engineering. pp. 1- 14, doi:10.1155/2007/92717. [5] Indrajith Mukharji,Pradip Kumar Ray(2006) ’A review of optimisation techniques in metal cutting process’Computers and Industrial engg.50,15-34. [6] G.Boothroyd,’Fundamentals of machining and machine tools’ 1sted,Scrapta Book Company’. [7] M. P. Groover, Fundamentals of Modern Manufacturing, Prentice-Hall.Inc. USA, 1996. AUTHORS B Tulasiramarao is a faculty member in mechanical engineering and pursuing phd in mechanical engineering. He is pursuing in the field of metal cutting in JNTU, Hyderabad from past 4 years and has three other research publications in this field, likely to submit in one year Dr.K.Srinivas the other is a professor in mechanical engineering for the past 16 years he is in the research field, His area of research includes metal cutting and thermal engineering. . He is working as a Professor in the Department of Mechanical Engineering, .R.V.R&J.C .College of Engg. ,Guntur, India. And he has published more than 25 research papers in various National/International Journals and Conference proceedings. Dr. P.Ram Reddy he is a professor in mechanical engineering and in the teaching field for the past 45 years . He has successfully guided 11 PH.D.S and has 109 research papers to his credit . He is arecipient of engineer of the year 2010 awarded by Govt.of A.P and Institute of engineers India ,Hyderabad Chapter.

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International Journal of Application or Innovation in Engineering & Management (IJAIEM) Web Site: www.ijaiem.org Email: [email protected], [email protected] Volume 3, Issue 9, September 2014 ISSN 2319 - 4847 Mr.Raveendra Akunuru is born in India, Andhra Pradesh. He received B.Tech (Mechanical) degree from R.E.C (Now National Institute of Technology) ,Warangal , Andhra Pradesh, India and M.Tech (Production Engineering) degree from Visveswaraya Technological University Belgaum, Karnataka, India. He is pursuing his doctoral study in Joining Processes at JNTU , Hyderabad, India. He is orking as Associate Professor in Malla Reddy Engineering College, Secunderabad. He has 5 years of Industrial experience along with 10 years of Teaching experience. His research interests in Pulsed Current TIG Welding. He is a life member of Indian Welding Society. Dr.B.V.R.Ravi Kumar received M.Tech (Design & Production Engineering) from R.E.C (Now National Institute of Technology) ,Warangal , Andhra Pradesh, India and Ph.D (Joining Process) from JNTU Hyderabad, Andhra Pradesh , India. He is working as a Professor in the Department of Mechanical Engineering, V.N.R.V.J.I.E.T , Hyderabad, India. And he has published more than 25 research papers in various National/International Journals and Conference proceedings.

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