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EXPERIMENT P1
Objectives
Figure 1 shows the geometry of the cutting zone and outlines the notation used to describe a bar
turning operation.
Flank face wear and Cutting (rake) face crater wear can be characterized using parameters as
outlined in Figure 3.
Flank Face
Usually criteria: a), b), and c) are quantitative and fundamental; while criteria c), d), and
e) are qualitative (they determine an end of tool life if they are excessive). f) implies an absolute
end of tool life if it occurs.
ME 3M02 – Experiment P1: Metal Cutting Processes P1-4
Values VB, KT depend on cutting conditions such as: material machined (machinability
rating - tensile strength, hardness, and microstructure), cutting speed V (m/min), feed s
(mm/rev), approach angle σ, geometry of tool (especially rake angle α) and length of machining
time.
VB = Fl (mat, V, s, α, t) (1)
KT = F2 (mat, V, s, α, t) (2)
Choosing maximum admissible wear values, VBlim, KTlim, the tool life T is obtained:
The smaller value of either T1 or T2 determines the end of tool life. Figure 4 describes a
typical wear curve of a cutting tool.
A change in the cutting speed also impacts the cutting process. This is due to the fact that
the temperature in the secondary deformation zone (close to the rake face of the tool)
continuously increases with cutting speed and therefore the deformation process in this zone
changes as a whole. Figure 5 captures the effect of a change in cutting speed (V) on tool wear
(VB) and tool life. Generally a tool wear limit of VB* is set (typical 0.25-0.35 mm) to determine
tool life T.
Figure 5: Effect of Cutting Speed (V) on Tool Wear VB and Tool Life (Bhattacharyya, 1984)
The most apparent phenomenon related to these changes in the cutting zone is the
occurrence of the Built Up Edge (BUE) on the tool. This phenomenon is shown in Figure 6.
With 1045 steel BUE starts occurring at speeds of about V=10 m/min. The probability of BUE
occuring increases with cutting speed until a speed is reached at which it is a maximum then with
further increases in V the probability of BUE decreases. After this point a thin built-up-layer may
formed on the face of the tool that varies with further increases in speed.
Figure 6: Built Up Edge (BUE) in Metal Cutting (Boothroyd and Knight, 1989)
ME 3M02 – Experiment P1: Metal Cutting Processes P1-6
Related to these changes are changes in friction between the chip and the tool, which
consequently changes the shear plane angle and impacts the components of the cutting force as
well. These are best expressed as changes of the chip ratio C, changes of surface roughness and
of the magnitude and direction of the cutting forces.
Usually the cutting forces are measured in a three-dimensional cut, i.e., both the major
and minor cutting edges are active as is the case in bar turning. In such cases it is desirable to
report the three principal force components as shown in Figure 7. Please refer to Figures 8-10
for details on the cutting force tool dynamometer.
References:
Bhattacharyya, A., Metal Cutting Theory and Practice, Central Book Publishers, Calcutta, 1984.
Boothroyd, G. and Knight, W. A., Fundamentals of Machining and Machine Tools, Marcel
Dekker, New York, 1989.
Elbestawi, M. A., Course notes for Machine Tool Analysis, McMaster University, 2002.
Stephenson, D. A. and Agapiou, J. S., Metal Cutting Theory and Practice, Marcel Dekker, Inc.,
New York, 1997.
ME 3M02 – Experiment P1: Metal Cutting Processes P1-7
Experimental Apparatus
Lathe: Colchester
Carbide Cutting Inserts
Tool holder
Micrometers, stop watch
Tool room microscope and tool fixture (flank wear)
Cutting force tool dynamometer (strain gauge based system)
Tail Stock
Cross Slide (Workpiece
(Tool post support)
Spindle mounting
(Workpiece point)
holding jaws)
Safety Rules
This material is largely taken from Mr. Ron Lodewyks’, Machine Shop / Project Laboratory
Safety Training Program.
Test Procedure
1) For the supplied material and a given depth of cut, feed rate and cutting speed measure:
a. two components of cutting force using the dynamometer (Ft, Fa).
b. the deformed chip thickness, procedure outlined below, to find the chip ratio
i. Collect chips from each set of experiments
c. Make observations on the surface roughness of the workpiece
d. State of the tool (tool wear)
i. Be sure to collect the data as soon as the cutting force stabilizes so as to
minimize the accumulated tool wear on the cutting edge.
2) Next conduct a sensitivity analysis, repeating step 1 while adjusting each of the three
critical parameters (depth of cut, feed rate and cutting speed) up by one increment,
then up by double the increment and then down by an increment, then down by
double the increment. (ie. nominal , nominal + increment, nominal + 2 X increments,
… etc (see form 1). Total of 12 more cutting tests over the nominal)
3) Repeat the test this time till the tool wears out (VB*= 0.3 mm) for the set of conditions
which supplied the highest measured cutting force (highest wear condition) this time
carefully monitor the tool wear versus the actual distance traveled by the cutting edge.
Interrupt the cutting process periodically to measure the tool wear. (TA to supply a
reasonable distance). Record the BUE and tool wear in Form 2a as well as the chip
and force data in Form 2b
Details on Testing
Depth of Cut a = 1.5 mm (0.060 in) (increment 0.5 mm, 0.020 in)
Feed sr = 0 .25 mm (0.010 in/rev) (increment 80 μm, 0.003 in/rev)
Speed v = 120 m/min (400 feet/min) (increment 15 m/min, 50 feet/min)
measure on the chip given the irregular nature of the surfaces. To avoid a potentially inaccurate
measurement for h2 the value used in calculation is based on an average of measured values.
In this lab, the thickness is measured using a pointed-tip micrometer. Two measurements will be
made from different chips and the average will be used to calculate the chip ratio.
Another method that is sometimes used is as follows. The mean deformed chip thickness can be
estimated by measuring the length of the chip l2, its weight W, the width of cut b (assuming no
side spread) and knowing the specific density ρ of 1045 steel.
W
h2 =
ρ bl2
Requirements:
Required Graphs:
C vs. depth of cut
C vs. feed
C vs. speed
Ft, Fa & FResultant vs. depth of cut
Ft, Fa & FResultant vs. feed
Ft, Fa & FResultant vs. speed
Where the actual cutting distance (L) is the distance that the tool tip travels, taking into account
the rotation of the workpiece. A is the linear distance that the tool travels in the direction of the
workpieces axis and Sr is feed per revolution.
A
L= × 2π × Radius
Sr
Discussion of Results
Using metal cutting theory discuss the results summarized in the graphs. Comment on what
changes occur in the chip ratio C and how the change in cutting geometry affects force. Relate
this information to final part quality and metal removal rate (productivity).
P1-11
Form 1) Cutting test results Date: ______________ Name: ___________________________________
Cutting
Depth Feed per
Test Dia Speed/ Force Chip ratio calculation Comments
of cut rev
Actual
At the end of every time interval, make a sketch of the tool’s cutting edge that you observe in the microscope, see examples EX in the bottom
right corner
P1-13
Conditions:
Depth of cut = , Feed per rev = , N = __________, Dia = _________, Speed= ____________ (πDN)
Cutting Actual
Time
Time feed cutting Force Tool Wear Comments
interval
travel distance
T A L Fx Fz Fresult VB KT
# (BUE, Crater Wear, Surface Roughness etc.)
sec mm mm N N N mm mm
1
10