lab report onShaper

7/24/2019 lab report onShaper

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Lab Report on

Force measurement in a shaper machineusing dynamometer

Submitted by Submitted To

Sanatan Choudhury Dr. Abhay Sharma

Me15Mtech11015


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Contents:

1. Name of the Experiment.3

2.

Objective.3

3.

Introduction..3

4.

Specimen and equipment..5

5.

Working Principle.5

6. About Machine..6

7. Procedure.. 8

8.

Testing.9

9. Result9

10.

Conclusion.10

11.

Points to Remember..10


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Name of the Experiment:

Measurement of different forces in a shaper machine using tool dynamometer.

Objective:

To measure the forces of machining in a shaper using machine tool dynamometer.

To study the effect of different machining parameters on forces.

Introduction:

Machine tools are kind of machines on which metal cutting or metal forming processes

are carried out.

Material removal is essentially done on machine tools, which may be Lathe, Milling,

Drilling, Shaping, Planing, Broaching and Grinding machines.

The functions of machine tools are:

holding the workpiece

holding the tool

moving the tool or the work piece or both relative to each other,

supply energy required to cause metal cutting.

Every machine tool has a primary cutting tool for metal removal. And the different cuttingparameters are

Cutting Speed: Cutting speed is the distance traveled by the work surface in unit time

with reference to the cutting edge of the tool or the speed of tool with respect to the

workpiece. The cutting speed, v is simply referred to as speed and usually expressed in

m/min.

Feed: The feed is the distance advanced by the tool into or along the workpiece each time

the tool point passes a certain position in its travel over the surface. Feed f is usually

expressed in mm/rev. Sometimes it is also expressed in mm/min and is called feed rate.

Depth of cut: It is the distance through which the cutting tool is plunged into the

workpiece surface. Thus it is the distance measured perpendicularly between the

machined surface and the machined (uncut) surface or the previously machined surface

of the workpiece. The depth of cut d is expressed in mm.


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During machining different cutting parameters will affect the tool life, surface finish of

workpiece because depending on the parameters forces will be induced and heat will be

generated etc. So differentMachining tests are performed to get the effect of different

cutting parameters. The parameters which predominantly affect the tool life are cutting

speed, feed and depth of cut by the equation given by Taylor,


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The selection of cutting speed and feed is based on the following parameters:

Workpiece material

Tool Material

Tool geometry and dimensions

Size of chip cross-section

Types of finish desired

Rigidity of the machine

Types of coolant used

Specimen and equipment:

Sample workpiece

Tool with HCS tip Shaper machine

Tool dynamometer

Amplifier

Computer

Working Principle:

To measure the forces, the dynamometer will be placed at the location where the forces

have to be measured (in case of shaper under the workpiece). The working principle ofdynamometer is based on the principle of piezoelectricity. When the force is applied on

the quartzs crystal (piezoelectric material), it undergoes the strain and it will generate

emf across it in millivolts. While machining, the force exerted by the tool on the workpiece

in three different directions will strain the piezoelectric material in different amounts in

the three directions, which causes emf across them. This emf is sensed by the sensor and

sent to the amplifier, where it is amplified and sent to computer, where the forces will be

calculated and displayed.


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About Machine:

Shaper-

A shaper is a type of machine tool that uses linear relative motion between the

workpiece and a single-point cutting tool to machine a linear toolpath. Its cut is

analogous to that of a lathe, except that it is (archetypally) linear instead of helical.

The shaper gives us a wide variety of feeds, cutting speeds and depth of cut. It has

high degree of accuracy and rigidity, which are required for the metal machining

processes.

Different parts of a shaper machine are:

Tool feed handle-used to give the feed.

Tool post-used to hold the tool during operation.

Vice-used to hold the workpiece during operation.

Table-holds the vice.

Adjustable sliding support-for positioning of workpiece. (can move in x and z

direction)

Graduated collar-to adjust the stroke length.

Clutch handle-to engage and disengage of ram with driving unit.

Hand wheel-for manually operating the ram motion.


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Machine tool dynamometer-

A machine-tool dynamometer is a multi-component dynamometer that is used to

measureforces during the use of themachine tool.Empirical calculations of these forces

can be cross-checked and verified experimentally using these machine tool

dynamometers.

With advances in technology, machine-tool dynamometers are increasingly used for the

accurate measurement of forces and for optimizing the machining process. These multi-

component forces are measured as an individual component force in each co-ordinate,

depending on the coordinate system used. The forces during machining are dependent

on depth of cut, feed rate, cutting speed, tool material and geometry, material of the

work piece and other factors such as use oflubrication/cooling during machining.

Tool Dynamometer is a cutting force measuring instrument used to measure the cutting

forces coming on the tool tip of a shaper Machine. The sensor is designed in such a way

that it can be rigidly mounted on the vice and the workpiece can be fixed to the sensordirectly. This feature will help to measure the forces accurately without loss of the force.

Forces in X - Y - Z directions will be shown individually & simultaneously.
https://en.wikipedia.org/wiki/Dynamometerhttps://en.wikipedia.org/wiki/Forcehttps://en.wikipedia.org/wiki/Machine_toolhttps://en.wikipedia.org/wiki/Machine_toolhttps://en.wikipedia.org/wiki/Dynamometerhttps://en.wikipedia.org/wiki/Cutting_fluidhttps://en.wikipedia.org/wiki/Cutting_fluidhttps://en.wikipedia.org/wiki/Dynamometerhttps://en.wikipedia.org/wiki/Machine_toolhttps://en.wikipedia.org/wiki/Machine_toolhttps://en.wikipedia.org/wiki/Forcehttps://en.wikipedia.org/wiki/Dynamometer


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Procedure:

Fix dynamometer and workpiece (on top of dynamometer) on the shaper machineusing vice.

Switch on the machine.

Measure the work co-ordinates zero reference by touching the tool tip on top

surface of workpiece by using tool feed handle and hand wheel.

Ensure that tool tip is just touching the top surface of workpiece and moving freely

during the forward stroke using hand wheel.

Make all the necessary connections for the dynamometer required for

measurement.

Setting the parameters in dynamometer software:

Open the dyno ware software in the computer.

Select acquisition and select edit option to set the parameters of dynamometer.

After giving all the parameters and specifying the directory, where the results will

be stored, press apply and then ok.

Select view and select documentation to set the RPM of spindle. Ensure that the

RPM value in the software and the RPM value used in machine are same.

Select acquisition and then hardware.

Select send parameter, measure option, then apply and press ok. Select acquisition and then start.

Select apply and press ok.

Start shaper machine by slowly releasing the clutch handle and parallely give the

feed by using tool feed handle.

Simultaneously press go option in the computer to record the tool cutting force.


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Finally, Time vs Force graph will be plotted by software.

Testing:

In the current experiment

Experiment has been carried out on Aluminum workpiece.

At various depth of cut while the cutting velocity was held as constant, the forces

were measured using the dynamometer.

Result:

The results show that increasing feed rate increased cutting forces.


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Conclusion:

As a conclusion, the objective of this experiment is successfully achieved.

Points to Remember:

Dos Donts

1 Check all the connections properly. Dont go near machine.

2 Fix the dynamometer carefully. Dont give more depth of cut, it may

damage the dynamometer.

3 Slowly give the depth of cut.

4 Ensure no obstacle exists along the

tool travel length.

lab report onShaper

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