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Experiment-4: AIM: To Study The Effect of Cutting Speed, Feed Depth of Cut and Rake Angle On

The document discusses an experiment to study the effect of cutting speed, feed depth of cut, and rake angle on cutting ratio and shear angle. It describes the theory behind metal cutting and shear plane formation. It provides observations from experiments at varying speeds, feeds, depths, and rake angles and analyzes the effects of each parameter.

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Koushal Singh
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53 views7 pages

Experiment-4: AIM: To Study The Effect of Cutting Speed, Feed Depth of Cut and Rake Angle On

The document discusses an experiment to study the effect of cutting speed, feed depth of cut, and rake angle on cutting ratio and shear angle. It describes the theory behind metal cutting and shear plane formation. It provides observations from experiments at varying speeds, feeds, depths, and rake angles and analyzes the effects of each parameter.

Uploaded by

Koushal Singh
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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EXPERIMENT-4

AIM: To study the effect of cutting speed, feed depth of cut and rake angle on
cutting ratio and shear angle.
APPARATUS: Lathe, vernier calliper, cutting tool, thread, ruler.
THEORY:
Irrespective of basic nature of the chip obtained during machining of metal,
the main factor governing the formation of chips is the plastic deformation of
the metal by a shear process, the deformation of metal occurs along a plane
just ahead of the tool and running up to free work surface. After passing out
the shear plane, the deformed metal slides along the tool face due to the
velocity of cutting tool. The size of the shear zone is thick if the metal is
machined at low cutting speed and vice versa.

During orthogonal cutting, the tool moves with a velocity Vc against the work,
thereby shears the metal along the shear plane AB. The outcoming chip of
thickness t2 experiences two velocity components vf and vs along the tool face
and shear plane. The under-formed chip thickness t1 which is actually the feed
in certain machining operations. From the above configuration it is possible to
compute the value of shear angle (Ø) in terms of measurable parameter t1, t2
and γ.
From the right angled triangle, ∆ABC
AB=t1/sin(Ø)
Where Ø= shear angle
Further, from the right angles triangle, ∆ABD
Sin(90-Ø+ γ)= t2/ AB
AB= t2/sin(90-Ø+ γ)
AB=t2/cos(Ø- γ) where γ = Rake angle
OBSERVATIONS:
Diameter of workpiece, D=37 mm
Slot width= 1/8 inch= 0.3175cm=3.175mm
L1 =πD- slot width
= (116.2389-3.175)mm = 113.0639mm
Feed= 0.004 mm/rev
Rake angle= γ=16 ̊
SPEED(rpm) L2(mm) Rc= L2/L1 Ø
209 52 0.4599 26.846
409 57 0.5041 29.365
639 56 0.4952 28.859

Depth of cut(mm) L2 Rc=L2/L1 Ø


25 57 0.5041 29.365
20 56 0.4952 28.859
15 52 0.4599 26.846

Feed(mm/rev) L2 Rc=L2/L1 Ø
0.005 55 0.4864 28.363
0.0059 54 0.4776 27.859
0.004 57 0.5041 29.365
t1/sin Ø = t2/cos(Ø-γ)
t1/t2 = sin Ø/ cos(Ø-γ)
rc = sin Ø/ cos(Ø-γ)
rc = sin Ø/ (cosØ cosγ)+(sinγ sinØ)
1/rc = (cosγ cotØ)+sinγ
Where rc = cutting ratio
tanØ = rc cosγ/ (1- rc sinγ)
the chip thickness ratio can also be expressed in a different way. Let l2 length of
the cut chip which had a length l1 before cutting. As the volume remains
constant, it may be written that
l1t1b1=l2t2b2
where b1 is width of cut and b2 is width of chip
when there is no side flow of metal then b1=b2
Therefore,
l2xt2=l1xt1
l2/l1 = t1/t2
PROCEDURE:
1. Perform a turning operation on lathe using a sharp tool, perform
orthogonal cutting.
2. Obtain the chip produced.
3. With the help of a thread and a ruler, measure its length.
4. Using a vernier find its breadth.
5. Calculate t1/t2 using above given relations, hence find rc.
6. Calculate Ø using,
Ø=tan-1[ (rc cosγ)/(1-rcsinγ) ]
7. Perform the above steps at different speed, feed and depth of cut.
RESULT: The effect of cutting speed, feed, depth of cut and rake andle on
cutting ration(rc) and shear angle(Ø) has been studied.

DISCUSSION AND ANALYSIS:


Effect of cutting speed:
The cutting ratio increases as the cutting speed is increased. The chip
becomes thinner and area of shear plane is reduced. The forces required to
produce the chip becomes smaller as cutting speed is increased. As cutting
speed is increased, specific cutting energy reduces, resulting in higher
efficiency.
Effect of feed:
At longer feed, the specific cutting energy Ps and shear strength of the work
material τs remains constant, but at low feeds, Ps and τs both increase. This is
due to ‘tool-noise’ force.
Effect of Rake angle:
As the rake angle increases the shear angle also increases, the specific cutting
energy Ps reduce as rake angle α is increased. As α increases, the stress at the
tool chip interface decrease and since frictional stress remains constant. Β
increases.

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