TOBB UNIVERSITY OF
ECONOMICS AND TECHNOLOGY
MAK 307
Design and Manufacturing
LAB # 2
THEORY OF METAL CUTTING
EXPERIMENT REPORT
Members:
Group number
Name, Number
Name, Number
...
1. INTRODUCTION (20 Point)
In this section, the subject of the experiment should be mentioned and the purpose of the
experiment should be written. Then, technical information about the experiment should be given.
The following items are guidelines for the introduction section:






What is the machining, what is the importance of the machining?
What are the process parameters of the turning operation?
What is the surface roughness, how is it calculated, what is the importance of surface
roughness?
What is the cutting force and how is it calculated?
What is the cutting power and how is it calculated?
Why is lubrication used in machining hard materials?
2. EXPERIMENTAL METHOD (10Point)
The steps and the methods used in the experiment should be written briefly. Mention the process,
material, cutting tool used. Explain the process, control parameters and output measures briefly.
3. EXPERIMENTAL ANLAYSIS (50 Point)
3.1 Rough Cut Machining (25 Point)
3.1.1.First Cut
1) What are the process control parameters and their values? Explain on a sketch.
2) Estimate total theoretical process time. What is error% from measured time?
3) Estimate RMR?
4) Measure Average Total Power and Estimate Cutting Force (Fc) and Cutting Power(Pc)
using it.
5) Estimate theoretical Cutting Force (Fc) and Power(Pc) (Tip: Use orthogonal cutting
model)
6) What is error% of estimated Fc and Pc?
3.1.2 Second Cut
7) Double the depth of cut used in first cut. What are the new process control parameters
and their values?
8) Estimate RMR?
9) Measure Average Total Power and Estimate Cutting Force (Fc) and Cutting Power(Pc)
using it.
10) Estimate theoretical Cutting Force (Fc) and Power(Pc) (Tip: Use orthogonal cutting
model)
11) What is error% of estimated Fc and Pc?
12) What is the %improvement in RMR, and %increase in Pc?
3.2 Finish Cut Machining (25Point)
3.2.1 First Cut
1) What are the process control parameters and values? Explain on a sketch.
2) Estimate total theoretical process time. What is error% from measured time?
3) Estimate RMR?
4) Measure surface roughness using measurement device?
5) Calculate theoretical surface roughness?
6) What is error% of estimated Ra?
3.2.2 Second Cut
7) Run the experiment with doubling the cutting speed (V) and half the feed (f), write down
the new process parameters and values?
8) Estimate total theoretical process time. What is error% from measured time?
9) Estimate RMR?
10) Measure surface roughness using measurement device?
11) Calculate theoretical surface roughness?
12) What is error% of estimated Ra?
13) What is the improvement% for measured Ra by reducing the feed to half?
4. DISCUSSION AND CONCLUSION (20 Point)
In this section, errors occurring between measured and estimated values should be discussed.
Comment on what are the different objectives between a rough cut and finish cut.
Also write your concluding comments on the experiment and analysis.
5. REFERENCES
[1]
[2]
...