M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr.

Anwar Khalil Sheikh

Machining Processes
Parts are manufactured by removing or cutting
the materials from the work pieces
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 Tool
Generate Forces and Powers
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Objectives
1. To review the Turning and Drilling processes and the
process variables (speed, feed and depth of cut) in metal
cutting.

2. To familiarize the students with the force measuring
instrumentation and equipment.

3. To familiarize the students with the type and methods of
measuring forces in Turning as well as in Drilling
processes.

4. To study the effect of process variables on forces in metal
cutting.
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 tool
removes 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.

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Forces in Turning
Tangential or Cutting Force = F
z
Axial or Thrust Force = F
x

Radial Force = F
y
F
y
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 =
rpm N
rev mm f
mm d
,
. / ,
,
mm L
mm D
mm D
f
o
,
,
,
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Design of Experiments
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Experimental Setup
Dynamometer
Workpiece
Cutting
Tool
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Data Recording
Charge Amplifier
Data Acquisition and
Display
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

DynoWare
Data Accusation Software
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

DynoWare
Data Accusation Software
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Data Channels
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Acquisition parameters
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Channels Trigger
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Adding Cutting Parameters
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Hardware setting Display
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Press Meas Button first
then Press Go
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Computational Table
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Turning Vs Orthogonal Cutting
t
o
w F
c
F
t




f d F
z
F
x


M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Formulas in Turning
. sec
1000
. sec
60 1000
1
t an
3
1
mm
fdVx MRR
m
x
DN
V
rSin
rCos
t
f
r
c
=
=
|
.
|

\
|

=
=

t
o
o

t
o
and o are input known variables and t
c
is measured from experiment
Cutting force, F
c ,
and

Thrust force, F
t
are measured from Experiments
by using Tool Dynamometers.

Then;
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Calculation of Forces
o
R
F
t
F
c
F

N

|
Cutting
Tool
Chip
F
n
F
s
Tool Friction Force
F = F
c
sino + F
t
coso = R sin |
N= F
c
coso + F
t
coso = R cos |
Balanced Shear Force
F
s
= F
c
cos| - F
t
sin|
F
n
= F
c
sin| + F
t
cos|
Resultant Force
R=F
s
/Cos(|+ |- o )
Coefficient of friction
= F/N = tan | (0.52.0)
t
c
t
o
(|- o)
|
) (|
t
Sin
fd
A
A
F
s
s
s
=
=
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Power and HP in Metal Cutting
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Report Writing

1. Cover Page
2. Objectives of Experiment
3. List of Equipment and tooling
4. Neat and clean sketch of Experimental set up
5. 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 F
c
and F
t
vs Cutting speed (V) i.e., experiment number 1-6
9. Plot F
c
and F
t
vs Feed Rate (f) i.e., experiment number 7-12
10. Plot F
c
and F
t
vs Depth of Cut (d) i.e., experiment number 13-18
11. Develop empirical model of Fc given by the equation:
( )
( )
( )

|
o
d k Fc
V k Fc
f k Fc
3
2
1
=
=
=

12. Discussion of the Results
13. Conclusions and Comments
Conclude your report with the remarks, What you learned from the
experiment and any further improvement in the experiment.
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 workpieces
using a rotating tool with two cutting edges.
. drill bit or twist drill This rotating tool is called a
This operation is normally performed on a drill press.


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
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Force and Moment in Drilling
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: 2| =
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
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Experimental Setup
Dynamometer
Workpiece
Cutting
Tool
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Data Recording
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 POWER 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
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Drilling Vs Orthogonal Cutting
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Formulas in Drilling
746
) (
5
5 . 0
sec
60 4
sec
60 1000
3
2
Watts P
HP
MRR
P
u
Sin
Fz
F
D
M
F
Nn
V
T
mm
N
f D MRR
m
x
DN
V
t
t
t
t
c
L
=
=
=
~
=
=
=
|
t
t
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Report writing for Drilling

1. Cover Page
2. Objectives of Experiment
3. List of Equipment and tooling
4. Neat and clean sketch of Experimental set up
5. 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 F
z
and M vs Cutting speed (V) i.e., experiment number 1-6
9. Plot F
z
and M vs Feed Rate (f) i.e., experiment number 7-12
10. Plot F
z
and M vs Depth of Cut (d) i.e., experiment number 13-18
11. Develop empirical model of Fz given by the equation:
( )
( )
|
o
V k F
f k F
z
z
2
1
=
=

12. Discussion of the Results
13. Conclusions and Comments
Conclude your report with the remarks, What you learned from the
experiment and any further improvement in the experiment.