Download - Forrces in Truning and Drilling -131_2
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Machining Processes
Partsare manufactured by removing or cutting
the materials from the work pieces
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Cutting Forces and Power
Forces and Power requirements in metal cutting
must be known in advance to select a machine tool with enough power
select a cutting tool of withstanding the cutting
avoid excessive distortion, maintain dimensional tolerances
workpiece is capable of withstanding the cutting forces
without excessive distortion
Relative Movements Between Workpiece and Cutting ToolGenerate Forces and Powers
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Objectives
1. To review the Turningand Drillingprocesses and theprocess variables (speed, feed and depth of cut) in metalcutting.
2. To familiarize the students with the force measuringinstrumentation and equipment.
3. To familiarize the students with the type and methods of
measuring forces in Turning as well as in Drillingprocesses.
4. To study the effect of process variables on forces in metalcutting.
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Turning
Turning is a machining process performed on a lathe in which a single point toolremoves material from a rotating cylindrical workpiece. The cutting tool is fed
linearly and in a direction parallel to the axis of rotation of the workpiece as shown in
the figure below.
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Forces in Turning
Tangential or Cutting Force = Fz
Axial or Thrust Force = Fx
Radial Force = Fy
Fy
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Cutting Parameters in Turning
Original Diameter of Workpiece = Depth of Cut =
Final Diameter of Machined part= Feed rate =
Length of Cut on Workpiece = Rotational Speed = rpmN
revmmf
mmd
,
./,
,
mmL
mmD
mmD
f
o
,
,
,
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Design of Experiments
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Experimental Setup
Dynamometer Workpiece
Cutting
Tool
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Data Recording
Charge Amplifier
Data Acquisition and
Display
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DynoWare
Data Accusation Software
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DynoWare
Data Accusation Software
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12/33M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Data Channels
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Acquisition parameters
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Channels Trigger
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Adding Cutting Parameters
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Hardware setting Display
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Press Meas Button first
then Press Go
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Computational Table
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Turning VsOrthogonalCutting
to w Fc Ft
f d Fz Fx
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Formulas in Turning
.sec1000
.sec601000
1tan
3
1
mmfdVxMRR
mx
DNV
rSin
rCos
t
fr
c
toand are input known variables and tcis measured from experiment Cutting force, Fc, andThrust force, Ftare measured from Experiments
by using Tool Dynamometers.
Then;
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Calculation of Forces
RFt
Fc
F
N
Cutting
Tool
Chip
Fn
Fs
Tool Friction Force F = Fcsin + Ftcos = R sin N= Fccos + Ftcos = R cos
Balanced Shear Force
Fs= Fccos- Ftsin
Fn= Fcsin+ Ftcos Resultant Force
R=Fs/Cos(+ - ) Coefficient of friction
= F/N = tan (0.52.0)
tc
to
(- )
)(
Sin
fdA
A
F
s
s
s
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Power and HP in Metal Cutting
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Report Writing
1. Cover Page2. Objectives of Experiment3. List of Equipment and tooling4. Neat and clean sketch of Experimental set up5. A brief procedure of experiment (step by step)6. Complete the Table 1 and Table 2 by using the Microsoft Excel for each test condition.7. Sample calculation for one test by using the formulas.8. Plot Fcand FtvsCutting speed (V) i.e., experiment number 1-69. Plot Fcand FtvsFeed Rate (f) i.e., experiment number 7-1210.Plot Fcand FtvsDepth of Cut (d) i.e., experiment number 13-18
11.Develop empirical model of Fc given by the equation:
dkFc
VkFc
fkFc
3
2
1
12. Discussion of the Results13. Conclusions and Comments
Conclude your report with the remarks, What you learned from theexperiment and any further improvement in the experiment.
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Drilling Process
Drilling is used to create round holes in workpiecesusing a rotating tool with two cutting edges.
.drill bitortwist drillThis rotating tool is called a
This operation is normally performed on a drill press.
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Drilling Process Variables
f (mm/rev.)
N (rpm)
D (mm) n=number of teeth on cutter
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Force and Moment in Drilling
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Design of experiment in Drilling
TABLE 1: DATA SHEET DRILLING PROCESS
Workpiece Material: Twist Drill Material:
Material Spcific Energy: Ut W.s/mm3 Twist Drill Point Angle:
Using Coolant [Y/N] : Machine Tool Name: HP:
TEST ROTATIONAL AXIAL TWIST DRILL AXIL TORQUE
NO. SPEED FEED RATE DIAMETER FORCE or MOMENT
N (rpm) f (mm/rev.) D (mm) Fz (N) M (N-m)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Experimental Setup
Dynamometer
Workpiece
CuttingTool
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Data Recording
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Computational Table
TABLE 2: COMPUTATIONAL SHEET DRILLING
TEST CUTTING FEED TOOTH MRR FORCES (N) TOTAL TOTAL
NO. SPEED SPEED LOAD mm3/sec. CUTTING THRUST POW ER CUTTING
V (m/min.) F (mm/min) TL Fc Ft Pt (Watts) HP
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Drilling VsOrthogonal Cutting
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M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh
Formulas in Drilling
746
)(
5
5.0
sec604
sec601000
32
WattsPHP
MRR
Pu
Sin
FzF
D
MF
Nn
V
T
mmNfDMRR
mx
DNV
t
tt
t
c
L
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Report writing for Drilling
1. Cover Page2. Objectives of Experiment3. List of Equipment and tooling4. Neat and clean sketch of Experimental set up5. A brief procedure of experiment (step by step)6. Complete the Table 1 and Table 2 by using the Microsoft Excel for each test condition.7. Sample calculation for one test by using the formulas.8. Plot Fzand M vsCutting speed (V) i.e., experiment number 1-69. Plot Fzand M vsFeed Rate (f) i.e., experiment number 7-1210.Plot Fzand M vsDepth of Cut (d) i.e., experiment number 13-18
11.Develop empirical model of Fz given by the equation:
VkF
fkF
z
z
2
1
12. Discussion of the Results13. Conclusions and Comments
Conclude your report with the remarks, What you learned from theexperiment and any further improvement in the experiment.