Aluminium - Brass and Stainless Steel

Question: Discuss about the Report for Aluminium, Brass and Stainless Steel. Answer: Introduction In metal cutting industry, machining of products is major manufacturing processes. Industries are trying for improvement of the machine tool parameters so as to get better products at less cost. To achieve this in past several researches has been done to identify optimum condition for metal cutting. To get the optimum condition of machining quality some CNC machine tools are provided with adaptive controls system. It is system that modifies systems parameter online according to feedback. [Prabhu R., 2012] For enhancing the efficiency of machining processes getting optimize cutting forces is very important tasks. Machining parameter that affect power consumptions are depth of cut, cutting speed. Hence by focusing on this parameter by cutting forces measurement methods is expected to give significant impact on power reduction. These papers contain a brief analysis on the various effects of the cutting parameters on cutting force in the turning process. Improvement of cutting processes, optimization of the cutting parameter, and analysis of cutting technology are achieved by measuring cutting forces.[ Varalakshmi M.V.,2015] Experiment Procedure The job is fixed in chuck and flat the end face of work piece, operation facing is performed. For providing tapered hole job is drilled at centre so as to it be supported be the reference points. Dynamometer sensing unit is placed on CNC lathe by clamped it rigidly. Mount work-piece in chuck. Selected speeds in CNC controller to a suitable combination and start the machine. Wait for stabilizing, output of bridges and measured the maximum output for feed, thrust force. After that write readings.[ Prabhu R.,2012] Mechanics of metal cutting Metal cutting operation is performed by relative motion b/w cutting tool hard edge and the work piece. Cutting of metals can be done by multipoint cutting tool or single point cutting tool. Mainly by two kinds cutting of metal is performed that is oblique and orthogonal cutting. They are known as oblique and orthogonal. In orthogonal tool cutting edges angle is 90o to the direction vector of tools travel and if it is at an angle then known as oblique. For investigating cutting tool performance while cutting of metal, the cutting force measurement is very essential.[ Tulasiramarao B., 2014] Cutting forces Single point cutting tool have only single cutting force while machining but this force is further resolved into the two components so as for ease of the exploitation and analysis. Single force of cutting in turning is then resolved into two x-y components along the two orthogonal direction: X and Y[ Prabhu R., 2012]. These force components are-: Fx-: It is called thrust force act in radials direction. Fy-: That force is called cutting force that acts in feed direction (that is axial direction) Dynamometer Dynamometer measures cutting force in two perpendicular components while turning and that measured values are stored in computer with data acquisitions system. Dynamometer works on principle of the piezoelectric output in which charges proportional has to be measured. That charge is then passed through highly insulated cable to charge the amplifier to get conversions into the proportional voltage. A connection between in-line charge amplifier and dynamometer is of the paramount importance to measurement stability. Dynamometer output is amplified by charge amplifier and then data is collected in computer by mean of data acquisitions system.[ Varalakshmi M.V,2015] Work Piece Material used Aluminum Brass Copper Results Fx- Thrust cutting force in Newton Fy- Cutting force in Newton T- Time in seconds Conclusion From above research it is concluded that Stainless steel need highest amount of cutting force as compare to Brass and aluminum. Experimental analysis was performed on these materials at CNC turning machine tool. So this research paper describes reliable method to measure cutting forces during turning process with help of dynamometer. References Prabhu R.,2012 Effect of cutting Parameters on cutting force and surface roughness of Aluminum components using face milling process- a Taguchi Approach,ISOR Journal of Mechanical and Civil Engineering, ISSN: 2278-1684, Col. 3, Issue 4., Visited 10 Sep 2016, Available: https://iosrjournals.org/iosr-jmce/papers/vol3-issue4/B0340713.pdf?id=2561 Tulasiramarao B., 2014, Measuring cutting forces while cutting of different metals with different speeds, IJAIEM, ISSN 2319-4847, Volume 3, Issue 9, Visited 10 Sep 2016, Available: https://www.ijaiem.org/Volume3Issue9/IJAIEM-2014-09-28-66.pdf Varalakshmi M.V., 2015, Measurement of cutting forces while turning different materials by using lathe tool dynamometer with different cutting tool nomenclature, IJIRSET, ISSN: 2319-8753, Vol.4, Issue 7, Visited 10 Sep 2016, Available: https://www.ijirset.com/upload/2015/july/139_43_MEASUREMENT_NEW.pdf