Department of Mechanical Engineering

I.I.T. Kanpur

EXPERIMENT N0. 1

OBJECTIVE
To measure the cutting forces, tool temperature and shear angle during orthogonal cutting.

EXPERIMENT
Orthogonal cutting tests are carried out using a tube turning set-up on a lathe to study the effects of
cutting speed, feed rate and rake angle on cutting forces.
Orthogonal tube cutting tests are carried out using HMT lathe by(i). Varying cutting speed for constant feed rate and rake angle.
(ii). Using tool of various rake angles keeping feed rate and cutting speed constant.
Cutting forces are measured using a Piezo crystal type dynamometer, Nl DAQ card through LabVIEW
software figure 1.1 shown a schematic diagram for the measurement of cutting forces and tool chip interface
temperature. HSS tool and mild steel work piece are used for the experiments.
Shear angle is evaluated using the chip length ratio method. Tool temperatures are measured using toolwork thermocouple technique shown in Fig. 1.2.

BACKGROUND
In orthogonal cutting the cutting edge of the tool is perpendicular to the cutting velocity vector,
whereas in oblique cutting it is set at some angle other than 900 to the cutting velocity vector (Figure 1.3).
Using the following assumptions the free body diagram (Fig. 1.4) and Merchants circle diagram (Fig.
1.5) can be drawn:
1. Tool is sharp and chip flows only along the rake face.
2. Cutting edge id perpendicular to V (i.e., orthogonal cutting).
3. Shear occurs on a thin plane called the shear plane.
4. Continuous chip with out built up edge (BUE) is formed.
5. Material is rigid, perfectly plastic.
6. Coefficient of friction remains constant.
7. R and R are equal, opposite and collinear.
In Figures 1.4 & 1.5, F is the friction force, N is the normal force, F i is the shear force, Fn is force
normal to the shear plane, Fc is the cutting force, Ft is the thrust force, R and R are the resultant forces, is
the rake angle, is the friction angle, and is the shear angle.
Using Fig. 1.4, the theoretical values of forces can be estimated as;

Fc = Fs [cos(-)/cos(+-)]
Ft = Fc tan(-)
And

Fs = (tw)/sin
Where, is the yield shear stress of workpiece material.
Shear angle can be estimated from Merchants shear angle relationship

= /4 0.5(-)
Where, is the friction angle. (Take = 0.5 for mild steel HSS combination).
above equations gives.

Substituting for in the

Fc = 2wtcot; Ft = wt(cot2-1); = tan-1 = tan-1(F/N)

Where,

F = Fc sin + Ft cos; N = Fc cos - Ft sin

Shear angle is defined as the angle made by the shear plane with the cutting velocity vector V and
can be evaluated using the relation ship.

tan = (r cos) / (1 r sin)

where chip thickness ratio r = t/tc = lc/l, t is the uncut chip thickness, l is the uncut chip length, t c is the chip
thickness, lc is the chip length and is the rake angle.
Take a chip and accurately measure its length and weight. Using the volume constancy, the weight of
chip.

W = lc tc wc = ltw
Or

l=

W
tw

where, w is the width of cut.

Average tool temperature

p =

(1 A)W p
cvt u w ;

Wp = Fc v Frv;

A = 0.15 ln (27.5/ tan)

cvt
K

Where A is friction of primary heat which goes into the workpiece, is the density of the workpiece (7200
kg/m3 for mild steel), c is the specific heat (502 J/kg oC for mild steel), v is the velocity (= (DN)/60), D is

the mean diameter of the workpiece, N is the RPM of the workpiece and K is the thermal conductivity of the
workpiece (43.6 W/m oC for mild steel).

Figure 1.1: Schematic diagram for force and temperature measurements

Figure 1.2: A tool-work thermocouple circuit

Tool

(b) Oblique cutting

(a) Orthogonal cutting

Figure 1.3

(- )

Figure 1.4

Figure 1.5

Figure 1.6

PROCEDURE
1. Calibrate the dynamometer for the measuring forces in two directions. Plot the calibration curve.
(Calibration values are provided)
2. Calibrate the tool work thermocouple. (Calibration curve are provided Fig. 1.6)
3. Measure tool angles (b, s, and s) using the tool microscope.
4. Set-up the experiment and let the instruments warm up for 15 minutes.
5. Measure cutting forces and temperature varying (i) cutting speed, (ii) feed rate and (iii) rake angle.
6. Collect chip during experiments and measure their lengths and obtain their weights on a semi-micro
balance.

RESULTS
1. Evaluate the theoretical and experimental values of shear angles (1 and 2).
2. Evaluate the theoretical and experimental cutting forces and tool temperature.
3. Tabulate the results as shown below.
Tool material: HSS
Work material: MS
Shear strength: 400 N/mm2

Expt
.
No.

Rake
angle
(degrees
)

Cutting
speed
(m/min
)

Feed
rate
(mm/rev
)

Outside dia.: ..
Inside dia.: .
Tube thickness: .

Cutting
force,
Fc (N)

Thrust
force,
Ft (N)

Theo.

Theo.

Expt.

Shear
Tool tem.,
o
angle, b ( C)
(deg.)
Expt.

1 2

Theo
.

Frictio
n angle,
(deg)

Expt
.

REPORT
1. Present calculations for one set of reading and provide the tabulated results.
2. Plot the variation in experimental and theoretical cutting force, thrust force and tool temperature with
cutting speed and rake angle.
3. Plot experimental values of against ( - ) and show how the results compare with Merchants shear
angle relationship.
4. Sketch the dynamometer used and explain its working.
5. How the calibration of tool work thermocouple is carried out?

REFERENCES
1. Manufacturing Science by A. Ghosh & A. K. Mallik.

2. Introduction to Machining Science by G. K. Lal.