4.0 RESULTS AND DISCUSSIONS 4.

1 RESULTS

Figure 3: Formed Product

Diameter(mm) rough Spindle speed, N (rev/min) Feed rate, fr (mm/rev) Depth of cut, d (mm) 0.5 0.25 530.52

35 finish rough

25 finish

530.52

734.56

734.56

0.15

0.25

0.15

0.5

4.5

0.5

Table 1: Calculation data for straight turning

Machining Operations Central Drilled External Turning(D=36mm) External Turning(D=26mm) Groove Taper Knurling Threading

Cutting Tool Drill Facing Tool Facing Tool Parting Off Tool Facing A Double wheel Knurling Tool Thread Cutting Tool

Table 2: Machining operation selection and tools selection

Table 3: Material specification Parameter Cutting tool Cutting tool material Cutting speed for rough cut Cutting speed for finish cut Feed rate for rough cut Feed rate for finish cut Depth of cut for rough cut Depth of cut for finish cut Unit m/min m/min mm/rev mm/rev mm mm Data Facing tool Carbide 60 60 0.25 0.15 0.5 0.5

Table 4: Straight turning cutting condition data (D=36mm) Parameter Cutting tool Cutting tool material Cutting speed for rough cut Cutting speed for finish cut Feed rate for rough cut Feed rate for finish cut Depth of cut for rough cut Depth of cut for finish cut Unit m/min m/min mm/rev mm/rev mm mm Data Facing tool Carbide 60 60 0.25 0.15 4.5 0.5

Table 5: Straight turning cutting condition data (D=26mm)

Cutting condition

Unit

Formula

Calculation

Result

Max. spindle speed, N (rough cut) Avg. spindle speed cut, N (rough cut) Spindle speed, N (finish cut) rev/min rev/min rev/min

Material removal rate, MRR Table 6: calculation data for spindle speed (N), time (t) and material removal rate (MRR) for straight turning cutting condition (D=36mm) Cutting condition Max. spindle speed, N (rough cut) Avg. spindle speed cut, N (rough cut) Spindle speed, N (finish cut) rev/min rev/min rev/min Unit Formula Calculation Result mm3/min

Material removal mm3/min

rate, MRR Table 7: calculation data for spindle speed (N), time (t) and material removal rate (MRR) for straight turning cutting condition (D=26mm) Cutting parameter Spindle speed for rough cut Spindle speed for finish cut Feed rate for rough cut Feed rate for finish cut unit rev/min rev/min mm/rev mm/rev Calculated value 530.52 530.52 0.25 0.15 Machine value 530.0 530.0 0.24 0.13

Table 8: Machine default setting for straight turning cutting condition (D=26mm) Cutting parameter Spindle speed for rough cut Spindle speed for finish cut Feed rate for rough cut Feed rate for finish cut unit rev/min rev/min mm/rev mm/rev Calculated value 734.56 734.56 0.25 0.15 Machine value 880.00 880.00 0.24 0.13

Table 9: Machine default setting for straight turning cutting condition (D=26mm) Part Central Drilled External Turning(D=36mm) External Turning(D=26mm) Groove Taper Knurling Threading 5 30 36 26 Table 10: Part dimension Spindle Feed Surface Speed(rpm) Rate(mm/min) Roughness(Ra) Rough cut 530.0 0.24 0.307mm/rev Finish cut 530.0 0.13 0.090mm/rev Table 11: Surface roughness of rough and finish cut for straight turning operation (D=36mm) Operation
0

Dimension(mm) 3 36

Tolerance(mm) 7

Measurement Data(mm) 35.8

26

26.4

4 350 35.8 26.4

1.5

Spindle Feed Surface Operation Speed(rpm) Rate(mm/min) Roughness(Ra) Rough cut 880.0 0.24 0.111mm Finish cut 880.0 0.13 0.032mm e roughness of rough and finish cut for straight turning operation (D=26mm)

Tab le 12: Sur fac

ABSTRACT

Turning is one of the most common processes used in the industry. Any part with the cross section that is circular, and some that are non circular, can be turned. The surface finish of a turned part is primarily generated from process parameters such as feed, tool geometry and cutting speed. Process variables such as speed are often selected to provide high quality,often at the sacrifice of the productivity. From this lab we learned about the types of operation related to turning such as facing , taper turning, threading, cut off and knurling. From this lab we learnt about the types of cutting tool that have to use to the turning process. We have faced some problem when conducting this process such as there are some linings were found in the work piece after the turning process. This was because of the cutting speed that we have used was wrong, after set the correct cutting speed we didnt found this kind of problem. At last we have done our project in the fourth week.

1.0 INTRODUCTION 1.1 INTRODUCTON ( THEORY) Turning is the process whereby a single point cutting tool is parallel to the surface. It can be done manually, in a traditional form of lathe, which frequently requires continuous supervision by the operator, or by using a computer controlled and automated lathe which does not. When turning, a piece of material (wood, metal, plastic, or stone) is rotated and a cutting tool is traversed along 2 axes of motion to produce precise diameters and depths. Turning can be either on the outside of the cylinder or on the inside (also known as boring) to produce tubular components to various geometries. Although now quite rare, early lathes could even be used to produce complex geometric figures, even the platonic solids; although until the advent of CNC it had become unusual to use one for this purpose for the last three quarters of the twentieth century. It is said that the lathe is the only machine tool that can reproduce itself. The turning processes are typically carried out on a lathe, considered to be the oldest machine tools, and can be of four different types such as straight turning, taper turning, profiling or externalgrooving. Those types of turning processes can produce various shapes of materials such as straight, conical, curved, or grooved workpiece. In general, turning uses simple single-point cutting tools. Each group of workpiece materials has an optimum set of tools angles which have been developed through the years. The bits of waste metal from turning operations are known as chips. In some areas they may be known as turnings. 1.2 OBJECTIVES The objectives of the lab is to learn about the cutting condition in a turning process. From this lab we have learnt about the cutting speed that have to be used for the turning process. The cutting speed is different to each turning process.Apart fromthat we also have learnt about the types of operation that related to turning operation such as facing, taper turning, threading, knurling, cut off, boring and form turning.

RAW MATERIAL, EQUIPMENT AND SAFETY ATTIRE Raw material : Mild steel workpiece diameter 40 mm x 160 mm. Equipment : Lathe machine with accessories, cutting tools, hand tools, vernier caliper Safety attire : Safety goggle, safety shoe.

] W.K. Luk. Int. J. Mach. Tool Des. Res., 9 (1969), p. 17. Article | Scopus | | Cited By in Scopus (3)

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[2] N.N. Zorev, Metal Cutting Mechanics Pergamon Press, Oxford (1966), pp. 348377. [3] W. K. LUK, Int. J. Mach. Tool Des. Res. (in press).. [4] M. Kronenberg, Machining Science and Application Pergamon Press, Oxford (1966), pp. 235256. [5] A.S.M.E., . Manual on Cutting of Metals, (1952) Table 141. [6] A. Hornung. Gep., 5 6 (1953), p. 257.