EXPERIMENT 3

Cutting Force Measurement in Metal Cutting.

OBJECTIVE
a) Measurement of cutting forces and thrust forces for various speeds, feeds
and depths of cuts.
b) Study of the effects of process parameters (speed, feed and depth of cut)
on cutting forces.

MAJOR EQUIPMENT
Dynamometer and complete electronics setup:
Kistler Piezoelectric dynamometer
Amplifier
Dynoware software
Lathe Machine
Cutting Tool
Inserts (Carbide) TNMG160412CQ

THEORY
There are three types of forces which are involved when the facing operation
is performed. They are as follows:
Cutting Force - Fz
Thrust Force - Fy
Feed Force Fx
These three forces depend on three factors Speed, Feed and Depth of Cut.
These are measured with the help of a dynamometer. The variation of the
forces with time is a plotted using the software which is a part of the
electronic setup. The electronic setup also consists of an amplifier which
gives the values of the forces and also of the moment (torque) measured
through different channels. The cutting tool used to perform the facing
operation has an Insert made of carbide. In this experiment, Triangular Inserts
are used. To start with the experiment, some parameters have to be set
initially feed, time, cutting velocity etc.

OBSERVATIONS
Cutting tool insert code - TNMG160412CQ
Least count for depth of cut = 0.01mm
Time per reading = 10 seconds.
The readings of the three forces and their variation with feed were obtained
using the dynamometer and the electronic setup.
The readings were taken for the following feeds: 0.04 mm, 0.06 mm, 0.08
mm.

Depth
Feed Speed
of cut
[mm/rev] [rpm]
[mm]
147
0.04
190
247
147
0.5
0.06
190
247
147
0.08
190
247
147
0.04
190
247
147
1
0.06
190
247
147
0.08
190
247

Fx [N]
100.3
53.64
109
125.4
74.51
128
105.2
229.9
267.4
264.4
442.5
493.6
505.8
588.8
562.7
578.5
529
556.4

Vc
Vf (f*N)
Fy [N] Fz [N] (pi*D*N/1000)
[m/min]
[m/min]
247.8 281.8
23.61
5.88
154.8 192.4
30.51
7.6
235.9 293.1
39.66
9.88
321.5 387.4
23.23
8.82
252.3 336.4
30.51
11.4
371.9 380.8
39.66
14.82
233.8 418.4
23.23
11.76
626.2 582.2
30.03
15.2
691.9 585.1
39.03
19.76
297.7 464.7
20.90
5.88
387.6 561.6
27.01
7.6
413.4 595.9
36.39
9.88
536.6 736.9
21.66
8.82
549.3 740.8
27.99
11.4
543.7 696.6
36.39
14.82
714.6 937.9
22.49
11.76
714.8 848.7
29.07
15.2
613.3 805.3
37.79
19.76

Net
Diameter
Force
[mm]
[N]
388.43
51.14
252.70
51.14
391.71
51.14
518.81
50.33
427.05
51.14
547.45
51.14
490.70
50.33
885.40
50.33
944.76
50.33
611.95
45.28
813.29
45.28
877.29
46.92
1042.49 46.92
1094.17 46.92
1047.61 46.92
1313.38 48.73
1229.26 48.73
1155.09 48.73

From the above we can see the values of Fx, Fy and Fz are measured for a
period of 10 seconds. The variation of the Forces with Time can be seen in
the Graph plotted.

CONCLUSION
From the above set of observations and results, we conclude that cutting
forces vary with the speed, feed and depth of cut and also how these factors
have an impact on cutting force.