EXPERIMENT: 11
Aim: Force Measurement during Orthogonal Turning
Equipment : Lathe machine,Workpiece material (e.g., aluminum, steel),Cutting
tool,Dynamometer,Data acquisition system,Safety equipment (goggles, gloves).
Theory : Force measurement during orthogonal turning involves analyzing the cutting
forces acting on the tool and workpiece perpendicular to each other. The most common
approach is using dynamometers or force sensors attached to the lathe setup. The
measured forces can be related to the machining parameters, tool geometry, and material
properties to develop a theory for force prediction. This can help optimize cutting conditions
and tool design for improved machining efficiency and surface quality.
Fig.11.1 Dynamometer
Procedure :
1. Wear appropriate safety gear.
2. Set up the lathe machine with the required tool holder and cutting tool.
3. Secure the workpiece material in the lathe chuck.
4. Mount the dynamometer on the lathe carriage using appropriate fixtures.
5. Calibrate the dynamometer as per the manufacturer's instructions to ensure accurate
force measurement.
6. Connect the dynamometer to the data acquisition system.
7. Configure the data acquisition software to record and display the cutting forces.
8. Choose a suitable cutting tool geometry and material based on the workpiece material
and machining conditions.
9. Select cutting parameters such as cutting speed, feed rate, and depth of cut.
10. These parameters can be based on the material properties and desired experimental
conditions.
11. Start the lathe machine and allow it to reach the desired cutting speed.
12. Engage the cutting tool with the workpiece and begin the turning operation.
13. Record the cutting forces (axial and radial) displayed on the data acquisition system .
14. Ensure that the cutting conditions remain constant during the experiment.
15. Collect force data at regular intervals or time intervals, depending on the experiment's
design.
16. Ensure that the data collected includes cutting forces in both the axial and radial
directions.
17. Analyze the collected data to understand the relationship between cutting forces,
cutting parameters, and material behavior.
Observation table :-
S.NO. CUTTING SPEED FEED DEPTH OF Fc (N) Ft (N)
(M/MIN) (MM/REV) CUT (MM)
1.
2.
3.
4.
5.
LC _________
Calculation :
Calculate the specific cutting force using the formula: Specific Cutting Force (Kc) = Cutting Force /
(Depth of Cut * Width of Cut).
RESULT :-
Radial Force (Ft): This force component acts perpendicular to the cutting direction. It
represents the force required to shear the material and is usually the highest of the three
components. As you increase the depth of cut or feed rate, Ft tends to increase.
Tangential Force (Fc): This force component acts along the cutting direction and is
responsible for moving the chip away from the workpiece. Fc increases with higher cutting
speeds and feed rates.
Axial Force (Ff): This force component acts in the direction of the tool's axis and is related to
the tool's penetration into the workpiece. Ff increases with greater depth of cut.
These force measurements can be analyzed to optimize cutting parameters for achieving
desired surface finish, tool life, and efficiency in the machining process. Researchers and
engineers use this data to develop cutting force models and improve machining strategies.
PRECAUTUION :-
Safety: Always wear appropriate safety gear, including safety goggles and clothing, when
working with machining equipment.
Machine Setup: Ensure that the lathe machine is properly set up and in good working
condition. Check for any loose parts or abnormalities.
Tool Condition: Use a sharp and properly aligned cutting tool. Dull or misaligned tools can
lead to inaccurate force measurements.
Data Accuracy: Calibrate the force sensor accurately before starting the experiment to
ensure precise measurements.
Stability: Ensure the workpiece and cutting tool are securely fixed in place to prevent any
vibrations or movement during machining, as this can affect force measurements.
