APPLICATION OF MACHINE TOOLS

ASSIGNMENT 2
TABLE OF CONTENTS
TASK 1 ........................................................................................................................................................... 2
TASK 2 ........................................................................................................................................................... 3
TASK 3 ........................................................................................................................................................... 4
TASK 4 ........................................................................................................................................................... 5
TASK 5 ........................................................................................................................................................... 6
TASK 7 ........................................................................................................................................................... 8
Reflection .................................................................................................................................................. 8
Self-Assessment ........................................................................................................................................ 8
References .................................................................................................................................................... 9
TASK 1
A metal cutting tool is used to separate chips from the workpiece in order to cut the part to the required
shape and size. (Moltrecht, 1981). To be able to properly sever a chip from the workpiece the following
criteria must be met.

i. The tool has to be harder than the material to be cut

ii. The tools should be shaped such that its cutting edge can penetrate the work
iii. It should be strong enough to resist the cutting forces

Considering the drawing provided we can determine the cutting tools required to produce the parts.
Knowing that the material used for all the parts is Mild Steel, it is a given that a High-Speed Steel is the
material best suited to perform the cutting, as it is harder than Mild Steel. Different materials are cut
best under certain tool geometries.

Figure 1: Tool Geometries (Anon., n.d.)

For Mild Steel the geometries that suit it the best are as follows:

 Side relief of 12°

 End relief of 8°
 Side rake 12°-18°
 Back rake 8°-15°
The types of cutting tools depend upon the work required on the workpiece. For the parts we are
making the following tools will be needed.
i. Right hand roughing tool: this will be required to perform all the fast metal removal tasks such
as facing and turning. This can also be a let handed tool if required.

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 ii. Right hand knifing tool: This is used to finish the turning and facing operations, giving them a
smooth appearance with proper dimensional tolerance.
iii. Chamfering tool: Although chamfering can be done using a right handed knifing tool, using a
chamfering tool makes the operation much easier.
iv. Boring and Facing tool: this will be used to face and recess a large hole, like the one in the
center of Part one. It can plunge straight into a small drilled hole and will also face right across
the bottom recess. (Clark, 2013)
v. Knurling tool: This is used to produce the knurls seen on Part 2.

TASK 2
We know that we are turning a mild steel bar from a diameter of 2 inches, which is equal to 50.8mm=D0,
to 50mm=Df. From this we can evaluate the depth of cut d, which is:

𝐷0 − 𝐷𝑓 50.8𝑚𝑚 − 50𝑚𝑚
𝑑= = = 0.4𝑚𝑚
2 2
The Average diameter, ∅ is given by:

𝐷0 + 𝐷𝑓 50.8𝑚𝑚 + 50𝑚𝑚
𝐷𝑎𝑣𝑔 = = = 50.4𝑚𝑚
2 2
The surface or cutting speed, CS = 28m/min and the feed/tooth on average=0.05mm/rev. Also given is
the Specific energy, SE= 2W. s/mm3. To find the cutting force, Fc:

𝑇 ∗ 1000 ∗ 2
𝐹𝑐 =
𝐷𝑎𝑣𝑔
1000×𝐶𝑆 1000×28𝑚⁄min
We know that: 𝑁 = = = 176.84 𝑟𝑝𝑚
𝜋×∅ 𝜋×50.4
𝑆𝐸×𝑀𝑅𝑅
And Power Required: 𝑃𝑜𝑤𝑒𝑟 =
60
Where, 𝑀𝑅𝑅 = 𝜋 × ∅ × 𝑑 × 𝑓𝑒𝑒𝑑 ⁄𝑡𝑜𝑜𝑡ℎ × 𝑁 = 𝜋 × 50.4𝑚𝑚 × 0.4𝑚𝑚 × 0.05 𝑚𝑚⁄𝑟𝑒𝑣 × 176.84 𝑟𝑝𝑚 = 560 𝑚𝑚3⁄𝑚𝑖𝑛

Therefore, Power = 18.67W

So, 𝑃𝑜𝑤𝑒𝑟 𝐷𝑖𝑠𝑠𝑖𝑝𝑎𝑡𝑒𝑑, PD = Power × 60 = 18.67W × 60 = 1120 𝑁𝑚⁄𝑚𝑖𝑛
𝑃𝐷 1120
However, 𝑇 = = = 1𝑁𝑚
2𝜋×𝑁 2𝜋×176.84𝑟𝑝𝑚

Hence:

𝑇 ∗ 1000 ∗ 2 1 × 1000 × 2
𝐹𝑐 = = = 39.68
𝐷𝑎𝑣𝑔 50.4
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TASK 3
a) From Appendix C we can see that the proper cutting speed when turning Mild steel using a HSS
cutter with coolant should be between 28 m/min. (Anon., n.d.)
1000×𝐶𝑆
And we know that: Spindle speed, 𝑆 =
𝜋×∅

1000×𝐶𝑆 1000×28𝑚⁄𝑚𝑖𝑛
Therefore: 𝑆 = = = 4456.34 𝑟𝑝𝑚
𝜋×∅ 𝜋×20𝑚𝑚

b) We know that the required speed for a high carbon steel being milled by a 125mm HSS cutter is
18 m/min
1000×𝐶𝑆
Using the formula for spindle speed, 𝑆 = 𝜋×∅
= 1000×18𝑚
𝜋×125𝑚𝑚
⁄𝑚𝑖𝑛
= 45.84 𝑟𝑝𝑚

c) We know that the for a milling operation feed rate,𝑓 = 𝑆 × 𝑓𝑡 × 𝑚 ,where

S= spindle speed
ft=feed per tooth of cutter
m= number of teeth on cutter
From the table, we can see that a 25mm HSS cutter milling brass will require a spindle speed of
45 m/min and will have a feed per tooth of about 0.05-0.064 mm/tooth.

Therefore: 𝑓 = 𝑆 × 𝑓𝑡 × 𝑚 = 45 × 0.059 × 4 = 10.62 𝑓𝑒𝑒𝑑/𝑚𝑖𝑛

d) For a drilling operation, the feed rate is given by,𝑓 = 𝑆 × 𝑓𝑡 × 𝑚 , where m=1. We know
from data that the feed per tooth to drill a hole of 12mm will be between 0.037-0.05 mm.
To find the spindle speed we require the cutting speed for Aluminum which is 60m/min
1000×𝐶𝑆
Therefore, the spindle speed will be: 𝑆 = 𝜋×∅
= 1000×60𝑚/𝑚𝑖𝑛
𝜋×12𝑚𝑚
= 1591.55𝑟𝑝𝑚

From this we can evaluate the feed rate to be:

𝑓 = 𝑆 × 𝑓𝑡 × 𝑚 = 1591.55𝑟𝑝𝑚 × 0.0435𝑚𝑚 × 1 = 69.23𝑓𝑒𝑒𝑑/𝑚𝑖𝑛

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TASK 4
When carrying out machining operations, all the tools used undergo wear which in extreme cases can
cause catastrophic failure. Most cutting tool failures occur by means of:

i. Mechanical breakage due to excessive forces and shocks. This kind of failure occurs abruptly and
can lead to catastrophic failure of the tool and hence is also fairly dangerous.
ii. Rapid dulling of the tool. This occurs by plastic deformation due to extreme stress on the tool. It
can also be caused by extreme temperatures. It can also occur abruptly, leading to detrimental
consequences and so is best avoided.
iii. Gradual wearing. This is the natural wear caused by regular use of the tool. It is mostly seen at
the rake and flanks of the cutting tool. This kind of wear is inevitable but can be prevented by
proper use and maintenance of the tool.

Now that the how of tool failure is settled, we can look at why tool failure occurs.

i. Cutting conditions: Conditions like speed, feed and depth of cut immensely dictate the
amount of wear that the cutting tool undergoes. A great way to visualize this is the use
of the Taylors equation, 𝑉𝑡 𝑛 = 𝐶. V= cutting speed, t= Tool life, n= constant depending
on depth of cut, cutting tool material and workpiece material and C = Taylor’s constant.
It is also evident that if the feed or depth of cut is increased, the cutting speed has to be
decreased to improve tool life. Vice-versa is also true. From this we can see that when
the cutting speed is increased the tool life decreases. So, a balance must be achieved
depending on the feed, depth of cut and cutting speed to achieve an optimal tool life.

ii. Tool geometry: Modifying the geometry of the tool also affects tool life. Increasing rake
angle reduces the cutting forces and the heat produced at the tool tip. This helps
increase tool life. On the other hand, increasing the rake angle by too much reduces the
amount of material available at the tool tip to conduct away heat thus keeping the tip
temperature high. This in turn reduces tool life. Therefore, a balance must be struck
between the two to achieve an optimal tool life.

iii. Tool material: the material that the cutting tool is made of contributes a fair amount to
how much wear it experiences. The main reason being hardness. Hardness determines
the amount of resistance to deformation a material has when compressive forces are
applied. Different materials have different hardness levels. Materials that are very hard
experience less wear compared to materials that are not as hard. As was the case for
our High-Speed Steel cutting tool. It experiences a lot more wear compared to other
much harder carbide tools. A materials response to high temperature also affects tool
life. Materials such as HSS have lower hot hardness compared to Carbides, thus they
undergo a lot more wear due to the heat produced from friction during operations.

iv. Cutting Fluid: Cutting fluid provides a means of heat dissipation between the tool tip
and workpiece. Heat dissipation plays an important role in maintaining a tools integrity
as explained above. The cutting fluid also provides some lubrication between the cutting
tip and workpiece, thus reducing the stresses experienced by the cutting tool, and so

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 reducing tool wear. One should also ensure that the fluid used is chemically inert so as
to avoid it reacting with the cutting tool material and causing catastrophic failures.

TASK 5
From the Taylor’s equation given,𝑉𝑡 𝑛 = 𝐶 , where:
V= Cutting speed

t= time

C= Taylor’s constant, which gives an idea of the tool life expectancy

n=other variables such as depth of cut and feed rate.

In our case: 𝑉𝑡 𝑛 = 𝐶 = 80𝑚 𝑚⁄𝑚𝑖𝑛 × (4ℎ𝑟𝑠 × 60)0.125 = 158.714

𝑡𝑛 (10ℎ𝑟𝑠×60)0.125
For the tool to last for 10 hours: 𝑉 = = = 71.342 𝑚⁄𝑚𝑖𝑛
𝐶 158.714

TASK 6
To make the Base, first take the 2-inch stock rod. Place it in the 3-jaw chuck and use a parting off tool to
cut it to 26mm. then face this cylinder to 24mm. then using a drill tool make a hole in the center of the
face. Use a reaming tool to increase the hole size to 20 mm in diameter. Using a chamfer tool, chamfer
both the edges of the face. Then flip the piece 90 ° and using a drill, drill a hole of 1mm all the way to the
center. Then take it of the lathe and use a M6x1.0 tap to make threads in the hole.

To make the Shaft, take the 1inch stock rod, place it in the jaw and face it on both sides. Then turn the
first 24mm of the rod to 20 mm diameter. Using a notching tool make a notch on this section of 6 mm
depth starting from the 1inch stock diameter. Then flip the rod 180° and secure it into the 3-jaw chuck.
Using the notching tool cut a second notch 2mm deep and extending a length of 50mm. then using a
drill, make a hole 20mm from the end of the rod, of 1mm. then using a M6 thread tap, make threads
inside the hole.

To make the retaining plate, take a flat bar of gauge 1.2mm. cut it to 21mm in length. Use a scriber to
mark out a line 11mm from the edge. Then using a bending machine bend the flat bar 11mm away from
the edge. Then drill a 8mm diameter hole at one edge, so as to form a half circle. Then drill another hole
of 4.2mm in diameter,16mm away from the first edge.

The adjustment screw is made from a 10-mm rod. The rod is placed in a 3-jaw chuck and turned to a
1mm in diameter for a length of 70mm. this end is the threaded to a M6 thread using a threading tool.

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The rod Is then flipped and the top part is knurled using a knurling tool. The edge is then chamfered to
2mm and 45°.

To make the Key, take a 6mm gauge square bar and cut it to 24mm in length. All the parts are then
assembled.

Figure 2: Completed Assembly

When carrying out this exercise I followed most of the safety and precaution guidelines provided,
including: Wearing appropriate gear when working in the workshop like overalls, safety boots. Safety
goggles and gloves. I also ensured that my workspace was kept clean so as to avoid unavoidable
accidents. Finally, I was always aware of my surroundings so as too not put my hands or feet in moving
machinery. However, I did make a few mistakes when performing this exercise. The first one was the
haste at which I worked. Not only was it dangerous, it also resulted in me making several mistakes which

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had to be corrected and so costing me precious amounts of time. Secondly, I did not follow protocol
when it came to the machining of the parts. I did not lay out a proper machining schedule and so got
confused a lot of times as to what I was supposed to be doing. This led to my finished product turning
out with several dimensional errors.

TASK 7
Reflection
After completing the production of the parts required, I noticed that the approach I used to establish my
manufacturing sequence had a few critical flaws. The first one was the choice of cutting tools. Some of
the tools that I chose were not essential; to the task. Like the right hand roughing tool and the
chamfering tool were not required as both their tasks could be accomplished using the right-hand
knifing tool. Using the same tool to perform several operations helped cut down on time required as the
tool post does not need to be constantly readjusted.

Tool geometry also plays a huge part in the efficiency of the production process and the quality of the
final product. In my plan I chose an end relief angle of 8°. However, after grinding the cutting tool, the
actual angle was about 5°. This meant that the cutting tool did not have enough material to conduct
away heat and so led to constant tool failure.

Although critical flaws did exist in the manufacturing sequence, most of it worked fairly smoothly. One
of them being the selection of the cutting speed, calculated using the Taylor’s equation. The speed
selected allowed for the tool to last the predicted amount of time and not fail prematurely.

This experience allowed me to understand how to properly plan and execute a manufacturing
sequence.it also taught me that the plan is just a guideline and Is not always to be followed to the letter.
When in practice one has to adapt to the situation, as unforeseen circumstances are inevitable.

In conclusion I feel that this entire assignment helped me achieve the necessary skills required to carry
out a manufacturing process in a machine workshop.

Self-Assessment
In this activity I was required to produce the product shown in Appendix A. This involved the planning of
the manufacturing sequence. This entailed the selection of the cutting tools required and the speed and
feed that was suitable for each of the operations that had to be performed.

During the planning phase I made the mistake of selecting more tools than necessary. This caused me to
waste a lot of time changing the tools on the tool post and resetting it. I also made the serious mistake
of not grinding my cutting tool to the proper angle, leading to higher cutting forces and temperatures,
which led to several critical failures of the tool. This also caused a lot of wastage of time.

The cutting speed that I chose, even though was suitable for the operation, was not fast enough. With a
bit more, experimentation I could have increased the speed of production by establishing a better
cutting speed.

In hind sight, other production methods could have been used to create the parts. Like using a milling
machine to create the notch on part one. This would have also allowed the possibility of working on two

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parts simultaneously. As the notch was being milled, the rod could have been turned and chamfered on
the lathe. This would have drastically improved productivity.

References
Anon., n.d. EML2322L – MAE Design and Manufacturing Laboratory. [Online]
Available at: http://www2.mae.ufl.edu/designlab/Lab%20Assignments/EML2322L-
Drilling%20and%20Milling%20Speeds%20and%20Feeds.pdf

Anon., n.d. Grinding HSS lathe tools.. [Online]

Available at: http://www.steves-workshop.co.uk/tips/toolgrinding/toolgrinding.htm

Anon., n.d. Speeds and feeds. [Online]

Available at: https://en.wikipedia.org/wiki/Speeds_and_feeds

Clark, D. A., 2013. Metal Turning on the Lathe. s.l.:Crowood.

Moltrecht, K. H., 1981. Machine Shop Practice, Volume 1. s.l.:Industrial Press Inc..