IIT BHU

Metal machining and

machine tools

STUDY OF METAL REMOVAL RATE WITH FEED

RATE
20/01/2016

NAME : Shubham Khatri

ROLL NO. : 14135077
CLASS : B. TECH. PART II, Semester IV
MECHANICAL ENGG.

SUBMITTED TO DR. MOHD. ZAHEER

STUDY OF METAL REMOVAL RATE WITH FEED RATE

What is Machining?
Machining is a manufacturing term encompassing a broad range of technologies and
techniques. It can be roughly defined as the process of removing material from a
workpiece using power-driven machine tools to shape it into an intended design. Most
metal components and parts require some form of machining during the
manufacturing process. Other materials, such as plastics, rubbers, and paper goods,
are also commonly fabricated through machining processes.

Types of Machining Process

Boring Process: In machining, boring is the process of enlarging a hole that has
already been drilled (or cast), by means of a single-point cutting tool (or of a
boring head containing several such tools), for example as in boring a gun
barrel or an engine cylinder. Boring is used to achieve greater accuracy of the
diameter of a hole, and can be used to cut a tapered hole. Boring can be viewed
as the internal-diameter counterpart to turning, which cuts external diameters.

Cutting process: Cutting is a collection of processes wherein material is

brought to a specified geometry by removing excess material using various kinds
of tooling to leave a finished part that meets specifications. The net result of
cutting is two products, the waste or excess material, and the finished part.

Drilling process: Drilling is a cutting process that uses a drill bit to cut or
enlarge a hole of circular cross-section in solid materials. The drill bit is a rotary
cutting tool, often multipoint. The bit is pressed against the workpiece and
rotated at rates from hundreds to thousands of revolutions per minute. This
forces the cutting edge against the workpiece, cutting off chips (swarf) from
the hole as it is drilled.

Grinding process: Grinding practice is a large and diverse area

of manufacturing and tool making. It can produce very fine finishes and very
accurate dimensions; yet in mass production contexts it can also rough out
large volumes of metal quite rapidly. It is usually better suited to the machining
of very hard materials than is "regular" machining (that is, cutting larger chips

with cutting tools such as tool bits or milling cutters), and until recent decades
it was the only practical way to machine such materials as hardened steels.

Milling process: Milling is the machining process of using rotary cutters to

remove material from a workpiece advancing (or feeding) in a direction at an
angle with the axis of the tool. It covers a wide variety of different operations
and machines, on scales from small individual parts to large, heavy-duty gang
milling operations. It is one of the most commonly used processes in industry
and machine shops today for machining parts to precise sizes and shapes.

Turning process: Turning is a machining process in which a cutting tool,

typically a non-rotary tool bit, describes a helical toolpath by moving more or less
linearly while the workpiece rotates. The tool's axes of movement may be
literally a straight line, or they may be along some set of curves or angles, but
they are essentially linear (in the nonmathematical sense).

Turning Process:
Turning is a form of machining, a material removal
process, which is used to create rotational parts by
cutting away unwanted material. The turning
process requires a turning machine or
lathe, workpiece, fixture, and cutting tool. The
workpiece is a piece of pre-shaped material that is
secured to the fixture, which itself is attached to
the turning machine, and allowed to rotate at high
speeds. The cutter is typically a single-point cutting
tool that is also secured in the machine, although
some operations make use of multi-point tools. The
cutting tool feeds into the rotating workpiece and cuts away material in the form of
small chips to create the desired shape.
Turning is used to produce rotational, typically axisymmetric, parts that have many features, such as holes,
grooves, threads, tapers, various diameter steps, and even
contoured surfaces. Parts that are fabricated completely
through turning often include components that are used in
limited quantities, perhaps for prototypes, such as custom
designed shafts and fasteners. Turning is also commonly

used as a secondary process to add or refine features on parts that were

manufactured using a different process. Due to the high tolerances and surface
finishes that turning can offer, it is ideal for adding precision rotational features to a
part whose basic shape has already been formed.
Different types of turning operations that are performed internally and externally:

Face turning or facing

Straight turning
Eccentric turning
Shoulder turning
Tapper turning
Grooving
Thread cutting
Cut-off
Drilling
Boring
Tapping
Reaming

Tooling
The various angles, shapes, and sizes of a single-point cutting tool have direct relation
to the resulting surface of a workpiece in machining operations. Different types of
angle such as rake angle, side rake angle, cutting-edge angle, relief angle, nose
radius exist and may be different with respect to the workpiece. Also, there are many
shapes of single-point cutting tools, such as V-shaped and Square. Usually, a special
toolholder is used to hold the cutting tool firmly during operation.

Turning Theory
Forces
The relative forces in a turning operation are important in the design of machine tools.
The machine tool and its components must be able to withstand these forces without
causing significant deflections, vibrations, or chatter during the operation. There are
three principal forces during a turning process:

The cutting or tangential force acts downward on the tool tip allowing
deflection of the workpiece upward. It supplies the energy required for the
cutting operation.The specific cutting force required to cut the material is
called specific cutting force.Cutting force is depends on the material.

The axial or feed force acts in the longitudinal direction. It is also called the
feed force because it is in the feed direction of the tool. This force tends to
push the tool away from the chuck.

The radial or thrust force acts in the radial direction and tends to push the
tool away from the workpiece.

Speeds and feeds

Speeds and feeds for turning are chosen based on cutter material, workpiece material,
setup rigidity, machine tool rigidity and spindle power, coolant choice, and other
factors.
Feed

The distance the tool advances into the material in one revolution is called
"feed". It is specified as mm per revolution (mm/rev).

Cutting speed for different metals:

Material type

MPM

SFM

Steel

15 to 18

50 to 60

Cast iron

18 to 24

60 to 80

Alloy steels

20 to 37

65 to 120

Carbon steels

21 to 41

70 to 130

Stainless steel

23 to 40

75 to 130

Bronze

24 to 45

80 to 150

Mil steel

30 to 38

100 to 125

Free cutting steels

35 to 69

115 to 225

Aluminum

75 to 105

250 to 350

Brass

90 to 210

300 to 700

Leaded steel

91

300

Cutting Parameter:
In turning, the speed and motion of the cutting tool is specified through several
parameters. These parameters are selected for each operation based upon the
workpiece material, tool material, tool size, and more.

Cutting feed - The distance that the cutting tool or workpiece advances during one

revolution of the spindle, measured in inches per revolution (IPR). In some operations
the tool feeds into the workpiece and in others the workpiece feeds into the tool. For
a multi-point tool, the cutting feed is also equal to the feed per tooth, measured in
inches per tooth (IPT), multiplied by the number of teeth on the cutting tool.

Cutting speed - The speed of the workpiece surface relative to the edge of the
cutting tool during a cut, measured in surface feet per minute (SFM).

Spindle speed - The rotational speed of the spindle and the workpiece in revolutions

per minute (RPM). The spindle speed is equal to the cutting speed divided by the
circumference of the workpiece where the cut is being made. In order to maintain a
constant cutting speed, the spindle speed must vary based on the diameter of the cut.
If the spindle speed is held constant, then the cutting speed will vary.

Feed rate - The speed of the cutting tool's movement relative to the workpiece as the
tool makes a cut. The feed rate is measured in inches per minute (IPM) and is the
product of the cutting feed (IPR) and the spindle speed (RPM).

Axial depth of cut - The depth of the tool along the axis of the workpiece as it makes
a cut, as in a facing operation. A large axial depth of cut will require a low feed rate,
or else it will result in a high load on the tool and reduce the tool life. Therefore, a
feature is typically machined in several passes as the tool moves to the specified axial
depth of cut for each pass.

Radial depth of cut - The depth of the tool along the radius of the workpiece as it
makes a cut, as in a turning or boring operation. A large radial depth of cut will require
a low feed rate, or else it will result in a high load on the tool and reduce the tool life.
Therefore, a feature is often machined in several steps as the tool moves over at the
radial depth of cut.

PROCEDURE

The work piece is fixed in the 4-jaw chuck with sufficient overhang.
Adjust the machine to run the job to a required cutting speed.
Fix the cutting tool in the tool post and do the centring of then workpiece so
that its axis coincides with the axis of the lathe machine.
Change the feed rate of the machine while keeping the RPM and the depth of
cut constant and measure the corresponding MRR BY weight loss.
Observe the variation (graphically) between feed and MRR.

Result and Discussion:

As it can be seen through observations that with increase in Feed the Metal Removal
Rate(MRR) increases.
This can be clearly visualized as the Feed increase more metal is removed per
revolution, and the time for which workpiece is subjected to turning remains
constant. This implies Metal Removal Rate(MRR) is directly proportional to Feed.