Manufacturing engineering –II(3341901)

EXPERIMENT NO: -2

AIM: To study about Effect of varying cutting parameters.

OBJECTIVES: After completing this experiment, you will be able to:
-Understand the types of chips
-Also understand the cutting parameters for work piece material and tool material.

Demonstrate type of chips:

Figure 1: types of chips form during lathe operations

Continuous Chips:
Continuous chips are formed by the continuous plastic deformation of metal without fracture in front
of the cutting edge of the tool and is formed by the smooth flow of the chip up the tool face. Mild steel
and copper are considered to be most desirable materials for obtaining continuous chips. The chips
obtained have same thickness throughout. This type of chip is the most desirable. Since it is stable
cutting, resulting in generally good surface finish. On the other hand, these chips are difficult to handle
and dispose of.
Continuous chips tend to be formed when the following condition exist:
1. Ductile material
2. High cutting speed
3. Small chip thickness
4. Large rack angle
5. Minimum friction of chip on tool face by:
 Polished tool face
 Use of efficient cutting lubricants.
 Use of tool material with low-coefficient of friction.

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Discontinuous or segmental chip:

Discontinuous chips are formed by a series of rupture occurring approximately
perpendicular to the tool place face’ each chip element passing off along the tool face
the chip element’ in the form of small segment may adhere loosely to each other and
becomes slightly longer.
Since the chips break up into small segments the friction between the tool and the chips
reduces’ resulting in better surface finish. These chips are convenient to collect’ handle
and dispose of. Discontinuous chips tend to be formed when one or more or the
following conditions exist:
1. Brittle material, such as cast iron and bronze.
2. Large chip thickness
3. Low cutting speed
4. Small rack angle
Discontinuous chips are also produced when cutting more ductile material with the use
of a cutting fluid.

Continuous Chip with Built up Edge:

This type of chip is very similar to the continuous chip. With the difference that it has a
built up edge adjacent to tool face and also it is not so smooth. It is obtained by
machining on ductile material, in this condition of high local temperature and extreme
pressure in the cutting and high friction in the tool chip interference, may cause the work
material to adhere or weld to the cutting edge of the tool. Successive layers of work
material are then added to the built up edge. When this edge becomes larger and
unstable, it breaks up and part of it is carried up the face of the tool along with the chip
while the remaining is left over the surface being machined, which contributes to the
roughness of the surface. The built up edge changes its size during the cutting operation.
It first increases, then decreases, then again increases etc.

Surface finishes for varying parameters:

Surface finish
The machining processes generate a wide variety of surface textures. Surface texture consists of the
repetitive and/or random deviations from the ideal smooth surface. These deviations are
Roughness: small, finely spaced surface irregularities (micro irregularities)
Waviness: surface irregularities of grater spacing (macro irregularities)
Lay: predominant direction of surface texture
Detailed information given in below figure,
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Figure 2: Surface roughness symbols and characteristics

Three main factors make the surface roughness the most important of these parameters:
Fatigue life: the service life of a component under cyclic stress (fatigue life) is much shorter if the
surface roughness is high
Bearing properties: a perfectly smooth surface is not a good bearing because it cannot maintain a
lubricating film.
Wear: high surface roughness will result in more intensive surface wear in friction.
Surface finish is evaluated quantitatively by the average roughness height, Roughness control
Factors, influencing surface roughness in machining are
 Tool geometry (major cutting edge angle and tool corner radius),
 Cutting conditions (cutting velocity and feed), and
 Work material properties (hardness).

The influence of the other process parameters is outlined below:

 Increasing the tool rake angle generally improves surface finish
 Higher work material hardness results in better surface finish

Tool material has minor effect on surface finish. Cutting fluids affect the surface finish changing
cutting temperature and as a result the built-up edge formation.
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Tools life for varying cutting parameters for same work piece material
and tool material:
The life of a cutting tool can be terminated by a number of means, although they fall broadly into two
main categories:

Gradual wearing of certain regions of the face and flank of the cutting tool, and abrupt tool failure.
Considering the more desirable case of the life of a cutting tool is therefore determined by the amount
of wear that has occurred on the tool profile and which reduces the efficiency of cutting to an
unacceptable level, or eventually causes tool failure. When the tool wear reaches an initially accepted
amount, there are two options,

 To reshape the tool on a tool grinder, or

 To replace the tool with a new one.

This second possibility applies in two cases,

1. When the resource for tool re-sharpening is exhausted. or

2. The tool does not allow for re-sharpening, e.g. in case of the index able carbide inserts

Taylor’s equation for calculating tool life,

VTn = C

V = Cutting speed,
T = Time,
n = Exponent, depends on tool and work material.
n = 0.1 – 0.2, H. S. S. tool.
= 0.2 – 0.25, Carbide tool.
= 0.4 – 0.55, Ceramic tool.

Parameters which affects tools life:

1. Cutting speed
2. Feed and Depth of cut.
3. Tool Geometry
4. Tool material
5. Type of Cutting Fluid
6. Work material
7. Rigidity of the Machine tool.
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Wear zones

Gradual wear occurs at three principal locations on a cutting tool. Accordingly, three main types of
tool wear can be distinguished,

1. Crater wear

2. Flank wear

3. Corner wear

Figure 3: Wear zone phenomena of cutting tool

Crater wear: consists of a concave section on the tool face formed by the action of the chip sliding
on the surface. Crater wear affects the mechanics of the process increasing the actual rake angle of the
cutting tool and consequently, making cutting easier. At the same time, the crater wear weakens the
tool wedge and increases the possibility for tool breakage. In general, crater wear is of a relatively
small concern.

Flank wear: occurs on the tool flank as a result of friction between the machined surface of the work
piece and the tool flank. Flank wear appears in the form of so-called wear land and is measured by the
width of this wear land, VB, Flank wear affects to the great extend the mechanics of cutting. Cutting
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forces increase significantly with flank wear. If the amount of flank wear exceeds some critical value
(VB > 0.5~0.6 mm), the excessive cutting force may cause tool failure.
Notch wear: occurs on the tool corner. Can be considered as a part of the wear land and respectively
flank wear since there is no distinguished boundary between the corner wear and flank wear land. We
consider corner wear as a separate wear type because of its importance for the precision of machining.
Notch wear actually shortens the cutting tool thus increasing gradually the dimension of machined
surface and introducing a significant dimensional error in machining, which can reach values of about
0.03~0.05 mm.

Tool wear is a time dependent process. As cutting proceeds, the amount of tool wear increases
gradually. But tool wear must not be allowed to go beyond a certain limit in order to avoid tool failure.
The most important wear type from the process point of view is the flank wear, therefore the parameter
which has to be controlled is the width of flank wear land, VB. This parameter must not exceed an
initially set safe limit, which is about 0.4 mm for carbide cutting tools. The safe limit is referred to as
allowable wear land (wear criterion),
The cutting time required for the cutting tool to develop a flank wear land of width is called tool life,
T, a fundamental parameter in machining. The general relationship of VB versus cutting time is shown
in the figure (so-called wear curve). Although the wear curve shown is for flank wear, a similar
relationship occurs for other wear types.
Parameters, which affect the rate of tool wear, are
Cutting conditions (cutting speed V, feed f, depth of cut d)
Cutting tool geometry (tool orthogonal rake angle)
Properties of work material

Tabulate observations
SR.NO VARYING MEASURABAL PARAMETERS
PARAMETERS
TYPES OF SURFACE FINISH(POOR,MIDIUM,GOOD)
CHIP
1
2
3