Manufacturing Methods 3B21 Revised July 2017
by
Mr N Madushele
MECHANICS OF MACHINING
PRACTICAL GUIDE
DEPARTMENT OF MECHANICAL ENGINEERING SCIENCE
FACULTY OF ENGINEERING AND THE BUILT ENVIRONMENT
UNIVERSITY OF JOHANNESBURG
Introduction
In manufacturing processes, machining can be defined as the process of removing
material from a work piece in the form of chips with the help of a cutting tool. The term
metal cutting is used when the material is metallic. Machining is necessary where tight
tolerances on dimensions and finishes are required. Material removal by traditional
machining operations has always been the workhorse of manufacturing industry.
During an orthogonal cutting operation, material is removed from the work piece with
the help of cutting force and cutting fluid as shown in Figure 1.
Figure 1: Material removal
Aim:
The aim of the practical is to provide a good understanding on the turning/milling
operation, setup parameters for a specific operation, tool geometry and wear
behaviour. Also, the understanding of the chips formed and tool wear. This will enable
the student to understand the operation of a Common Numerically Controlled (CNC)
machine, identify the type of chip formed during machining operation and to be able
to determine the tool life constant.
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However, to perform the operation, relative motion is required between the tool and
the work piece. This relative motion is achieved in most machining operation by means
of a primary motion, referred to as the cutting speed and a secondary motion referred
to as the feed. The shape of the tool and its penetration into the work surface,
combined with these motions, produce the desired shape of the resulting work surface.
Before you begin the experiment, measure the dimensions of your sample with
a Vernier calliper. Take note of the feed rate, speed of cut, the cutting tool, the
type of specimen. The cutting fluid must be ON during the operation to reduce
the heat generated during cutting.
At the end of the practical, you are required to record the data used for the operation
in the below Tables. At least two feed rates should be used for each group.
Table 1: Experiment results obtained during the Machining experiment
Test Number Feed Rate Speed of Cut Machining Tool bit Wear
(mm/Rev) (m/min) Time (Sec) (m)
Table 2: Estimated tool life for 0.35m tool bit wear
Cutting speed (m/min) Tool Life ( s )
Generate the following graphs and answer the preceding questions:
1. Tool wear plotted against the cutting speed.
2. Tool wear plotted against Machining time.
3. The logarithm of tool life plotted against the logarithm of cutting speed.
4. Determine the values of constants n and C making reference to Taylors tool
life equation.
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5. Predict the tool material used for the cutting base on your value of n and C.
6. From your graph determine the value of cutting speed that will make the life
span of the tool to be 50hours.
7. From your graph determine the maximum cutting speed.
8. State 5 precautions that was ensured while performing the experiment in the
laboratory.
9. You are required to determine the following:
Type of chip formed (Attach a photo)
The nature of the tool wear.
TO BE HANDED IN:
The report shall include the following:
Title/cover page
Plagiarism declaration
Table of contents
Introduction - Aim
Literature review
Experimental set-up,
Experimental Procedure/Methodology
Experimental results and Discussion
o Presented in Tables and Graphs
Conclusion
References
Reports are to be handed in a week after the experiment was conducted.
NOTE: You are required to hand in the practical reports as groups of five.
Remember to indicate your names (surname and initial), student numbers and
practical group numbers on the front page cover of your reports. All members
of the group must sign the plagiarism declaration page otherwise; the report will
not be marked.
Good luck!
