ESCUELA SUPERIOR POLITCNICA DEL LITORAL

LAB REPORT OF MACHINIG PROCESS

EFFECTS OF CUTTING SPEED AND FEED IN ORTHOGONAL CUTTING MODEL

NAMES:
RICHARD BRICEO MALDONADO
JOSU GAVILANES TRIVIO

PRACTICE REALIZATION DATE: 9/11/2010

REPORT DELIVERY DATE: 16/11/2010

II TERM YEAR 2010-2011

Contents
Objectives.............................................................................................................. 3
Introduction............................................................................................................ 3
Principles and practice............................................................................................... 3

Process Practice....................................................................................................... 4
Results.................................................................................................................. 4
Conclusion............................................................................................................. 5
Recommendations.................................................................................................... 5
Bibliography........................................................................................................... 5
Apendix................................................................................................................. 6
PART A.............................................................................................................. 6
Calculation...................................................................................................... 6
Program for plot in MATLAB................................................................................ 6
Graphs............................................................................................................ 6
PART B............................................................................................................. 12

Objectives
1. To introduce the use of the CNC Lathe on CAMPRO
2. To acknowledge the impact of cutting speed and feed changes on other orthogonal cutting
model parameters
3. To acknowledge the impact of cutting speed and feed changes on workmaterial surface
finish (by merely observation)
4. To obtain graphs and to conclude base on obtained results

Introduction
The material SAE 40 is used in various manufacturing processes, so it's always going to be
machined on a lathe. At around the material will be brought to the way we want, always considering
that for any type of turning, the material we have to have a good surface finish. But to have that
good surface finish is necessary considerer factors that directly affect the surface finish; the most
important are the feed rate and cutting speed, which then study their effects.
Principles and practice
Let's use a CNC lathe to machine a material. The CNC lathe is a lathe which operates under the
guidance of a computer. We only do is put in a panel different parameter values to machine the
piece, for example the value of the cutting speed (RPM), the value of the depth of cut (u), the value
of length (w) or the feed rate (F), etc., once we in the required data for each measurement, we give
the order to start working the lathe, where through programs controlled by alpha-numeric data,
executes order successfully. But as we will be able to study the effects produced by changing the
value of the parameters of cutting speed and feed, so that we do use the following equations:
Unit Power Energy [Pu].- Which represents the force by volume unit need to remove material.

Pu=

Fc
to w

Chip Thickness ratio [r].- The relation between the thickness of chip before and after cut.

r=

to
tc

Shear stress [] .- Is produced in the machining process.

F c cos ( )F t sin ( )
to w
sin ( )

When study the effects produce by changes on cutting speed and feed you may notice that more
significant changes will be produce while working at a lower range of speed. Higher speeds will
tend to stabilize conditions little by little. Experimentally will be of more benefit to select individual
speeds on geometric progression and graph the final results on a logarithmic scale. This way the
results will be obtaining equally space.
In order to observe the effects in feed and initial chip thickness it is desirable to cover a range as
wide as possible; maybe the best procedure will consists in select equally space increments from the
lower to the higher feed velocity, all this, with the higher cutting speed.
For this practice we know the data of:
Cutting force [Fc]= 1100 N
Thrust force [Ft]= 985 N
Angle alpha []= 15

Process Practice
For each data of cutting speed we will work with four feeds, in total we will work with four
different cutting speeds, it means that in total we will have sixteen measurements. For doing the
respective calculus we need some values, these are cutting force and thrust force which will be
given by the instructor during the practice, these values are:
The chip measurement can be performed with a caliper or micrometer, but in our case we will use
an approximation which says that the value of feed is equivalent at to (thickness chip before
cutting).
Finally, after these 16 measures, material will be change and you will verify visually what the
change is in surface finish with the following conditions:
High cutting speed, high feed
Low cutting speed, low feed
High cutting speed, low feed
Low cutting speed, high feed
Combinations
Speed (RPM)
1500(H)
350(L)
1500(H)
350(L)

Feed (mm/rev)
0.5(H)
0.01(L)
0.01(L)
2(H)

H=High, L=Low.
Results
Case 1
Vc = 0.05
to

[mm]
0,050
0,125
0,250
0,375

tc

[mm]

[mm]

0,075
0,134
0,290
0,391

0,500
1,000
1,500
2,000

[m/ seg]

N [ RPM ]
36
38
39
40

0,67
0,93
0,86
0,96

37,87
49,86
46,94
50,89

Pu

[ N /mm2 ]

[Pa]
44,0E+9
8,80E+09
2,93E+09
1,46E+09

6476,77
-268,42
60,87
-72,90

Case 2
Vc = 0.1
to

[mm]
0,050
0,125
0,250
0,375

tc

[mm]

[mm]

0,0770
0,1380
0,3100
0,3990

1
2
3
4

[m/ seg]

N [ RPM ]
79
86
94
105
Case 3

0,65
0,91
0,81
0,94

36,99
48,77
44,51
50,14

Pu

[ N /mm2 ]

[Pa]
2,20E+10
4,40E+09
1,47E+09
7,33E+08

3441,20
-47,48
87,70
-26,13

Vc = 0.2
to

[mm]
0,050
0,125
0,250
0,375

tc

[mm]

[mm]

0,0790
0,1410
0,3600
0,4020

1
2
3
4

[m/ seg]

N [ RPM ]
268
311
371
411

0,63
0,89
0,69
0,93

36,15
47,97
39,25
49,86

Pu

[ N /mm ]

[Pa]
2.20E10
4,40E+9
1,46E+09
7,33E+08

3624,41
13,97
192,91
-22,37

Case 4
Vc = 0.4
to

[mm]
0,050
0,125
0,250
0,375

tc

[mm]

[mm]

0,0830
0,1450
0,3720
0,4080

1
2
3
4

[m/ seg]

N [ RPM ]
822
921
1047
1213

0,60
0,86
0,67
0,92

34,56
46,94
38,14
49,31

Pu

[ N /mm ]

[Pa]
2,20E+10
4,40E+09
1,47E+09
7,33E+08

3938,15
91,31
211,56
-15,03

Conclusion
With practice made we realize what the energy it takes to start a number of chip, for this
opportunity all energies were equal in their behavior, by this we mean that the first value was the
maximum and was decreasing after because the To and w were increasing in magnitude values of
the first case were the only ones that differed from the others and this case is that in the first part
used
a
0.5
mm
depth
of
cut.
The effort to machining operations is a fact that no clear trend and it begins with a rather high
value and then can drop to negative and then rises again, this is because working with cosine angles
within and these are functions that rise and fall constantly and also because r is a fact that is not
linear and that Tc does not allow it, perhaps this Tc in some cases is wrong.
In the second part of the practice note we focus on the finish, for this we tested the four ways you
can change both speed and feed, giving us that for this type of cutting tool and work material, the
way to get a better finish is to apply a high speed and little feed since it was observed that the finish
was as if It was doing a polished, minor scratches to the final note that might not have appeared if
the work surface had not been so bad at Start the machine or if the depth of cut applied to work
would have been higher. Keep in mind that for each variable material characteristics to be applied to
obtain a good finish and also depends on the type of blade used.
Recommendations
-Center-right piece of work for when measured with vernier gauge the diameter is uniform and
equal to the theoretical calculations.
-Measure Tc more precisely and repeatedly to be sure, since this is a fact that affects the entire
practice
-When using higher speeds and feeds, you must apply small depth of cut to prevent that insert split
up.

Bibliography

http://www.elprisma.com/apuntes/ingenieria_mecanica/arranquedeviruta/
http://www.scribd.com/doc/7993250/TORNEADO
http://www.fimcp.espol.edu.ec/backup/Procmecan_site/cort_met_form.htm

Apendix
PART A
Calculation

0.05
r= =
=0.67
tc 0.075
=tan

Pu=

r . cos
1 0.67cos 15
0
=tan
=37.87
1rsin
10.67sin 15

1100[ N ]
Fc
=
=4.4 (10)9 [Pa]
tow 0.05 [ mm ] .0 .5 [mm ]

( 1100 ) . cos ( 37.87 0 )( 985 ) . sin(37.87 0)

N
=
=6460.35 [
]
0
2
(0.05).(0.5)/sin (37.9 )
mm
Program for plot in MATLAB
x = [0.05 0.125 0.250 0.375];
y = [3938.15 91.31 211.56 -15.03];
cs = spline(x,[0.733 y 22]);
xx = linspace(0.05,0.375,101);
plot(x,y,'o',xx,ppval(cs,xx),'-');
xlabel('to(mm)')
ylabel('Thao(N/mm2)')
Graphs
Case 1

Pu vs t 0

r vs t 0

vs t 0

Case 2

Pu vs t 0

r vs t 0

 vs t 0

Case 3

Pu vs t 0

r vs t 0

vs t 0

Case 4

Pu vs t 0

r vs t 0

 vs t 0

PART B

Combinations
Speed (RPM)
1500(H)
350(L)
1500(H)
350(L)

Feed (mm/rev)
0.5(H)
0.01(L)
0.01(L)
2(H)

High v, low f

High v,

Low v, low f

Low v, high f