Production Engg Lab Manual (V Semester) Lathe Tool Dynamometer

Production Engg Lab Manual (V semester) Lathe tool dynamometer
EXPERIMENT NO:- 10
Aim: (a) By using lathe tool dynamometer measure the cutting forces in all directions.
(b) Analysis of effect of the process parameters, cutting speed, feed rate and depth of cut
on cutting forces during turning operation.
Equipments used-Lathe machine, Lathe Tool Dynamometer, Cutting tool, Job piece.
Theory
1 Cutting force components and their significances
The single point cutting tools being used for turning, shaping, planing, slotting, boring etc. are
characterised by having only one cutting force during machining. But that force is resolved into
two or three components for ease of analysis and exploitation. Fig. 1 visualises how the single
cutting force in turning is resolved into three components along the three orthogonal
directions; X, Y and Z.
Figure 1: Cutting forces during turning
These three components are:
Cutting force (Ft) acts in tangential direction. It is also called power component as it being
acting along and being multiplied by cutting speed (VC) decides cutting
power (PZ.VC) consumption.
Feed Force (Fa) acts in the direction of feed (axial direction). Generally, this force is small in
magnitude but is responsible for causing dimensional inaccuracy and
vibration.
Thrust Force (Fr) acts in radial direction. This force is least harmful and hence least significant.
1
2 Need for determination of the cutting forces:
Cutting force determination is required for
• Estimation of cutting power consumption, which also enables selection of the power
source(s) during design of the machine tools
• Structural design of the machine –fixture – tool system
• Evaluation of role of the various machining parameters (process –Speed (VC), feed (f),
depth of cut (t), tool —material and geometry, environment — cutting fluid) on cutting
forces
• Study of behavior and machinability characterisation of the work materials
• Condition monitoring of the cutting tools and machine tools.
Lathe Tool Dynamometer:
When force is applied to a structure, the length of the structure changed. Strain is the ratio of
this change in dimension to the original, and strain gauges are used to measure it. If a strain
gauge is glued to the structure, any distortion to the structure will also cause a distortion of the
strain gauge. The gauge contains conducting material and the distortion therefore results in a
change in its resistance. By measuring this change in resistance we can measure the strain.
Strain gauges are frequently used in mechanical engineering research and development to
measure the stresses generated by machinery. Aircraft component testing is one area of
application wherein tiny strain-gauge strips are glued to structural members, linkages, and any
other critical component of an airframe.
Construction
Strain gauges are used in two forms, wire and foil. The basic characteristics of each type are the
same in terms of resistance change for a given strain. The design of the SG itself is such as to
make it very long in order to give a large enough nominal resistance (to be practical) and to
make the gauge of sufficiently fine wire or foil so as not to resist strain effects. Finally, often the
gauge sensitivity is made unidirectional, that is, it responds to strain in only one direction.
These gauges are usually mounted on a paper backing that is bonded (using epoxy) to the
element whose strain is to be measured. The nominal SG resistances (no strain) available are
typically 60, 120, 240, 350, 500, and 1000W. The most common value available is 350W.
2
Procedure
1 The Lathe Tool Dynamometer is initially set to zero reading.
2. Three different types of tests were done to measure the cutting force on the cutting
tool.
 The first test consisted of keeping the feed and depth of cut same and changing
the cutting speed of the lathe. Four different speeds were used for this test.
 The second test consists of varying the feed and keeping the cutting speed and
depth of cut the same. Five different feed rates are used for this test.
 The third test consists of varying the depth of cut while keeping the cutting speed
and feed same. Five different depth of cut are used for this test.
3. For each set data are acquired and documented in the table for further analysis.
Observation table-
Initial diameter of the bar = mm
Bar material =
Cutting tool material =
Depth Sign of
Speed Feed
S.No. of Cut PU1(kgf) PU2(kgf) PU3(kgf) Teacher
(rpm) (mm/rev.)
(mm)
Result-
Graphs can be plotted for different sets of depth of cut for further analysis.
(a) Cutting Force Vs Depth of Cut

(b) Feed Force Vs Depth of Cut
(c) Thurst Force Vs Depth of Cut
Conclusions
3
Sample Questions
1. Explain the principle of lathe dynamometer
2. What is the sensing element in dynamometer?
3. Why do you measure cutting forces on lathe?

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Production Engg Lab Manual (V semester) Lathe tool dynamometer

1 Cutting force components and their significances

Figure 1: Cutting forces during turning

These three components are:

2 Need for determination of the cutting forces:

Cutting force determination is required for

• Structural design of the machine –fixture – tool system

• Study of behavior and machinability characterisation of the work materials

• Condition monitoring of the cutting tools and machine tools.

Lathe Tool Dynamometer:

1 The Lathe Tool Dynamometer is initially set to zero reading.

Cutting tool material =

(a) Cutting Force Vs Depth of Cut

2. What is the sensing element in dynamometer?

3. Why do you measure cutting forces on lathe?

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