SIR C R REDDY COLLEGE OF ENGINEERING

6.MEASUREMENT OF CUTTING TOOL TEMPERATURE IN

TURNING

Aim:
To measure cutting tool temperature in turning using thermocouple with digital
indicator

Equipment Required:
Tool tip temperature thermocouple with digital indicator

Tools & Material Required:

1) Dia 25mm x 100mm length M.S.Round
2) Single point cutting tool

Theory:

Thermo – Electric Sensor:

The most common electrical method of temperature measurement uses the thermo -
electric sensor also known as the thermocouple. The construction of the thermocouple
consists of two wires of different metals twisted and brazed or welded together with each
wire covered with insulation, which may be either:

1) Mineral (Magnesium oxide) Insulation for normal duty, or

2) Ceramic insulation for heavy duty.

The basic principle of temperature measurement using a thermo - electric sensor was
discovered by seebeck in 1821, when two conductors of dissimilar metals, say A & B are
joined together to form a loop (thermocouple) and two unequal temperatures T 1 and T2 are
interposed at two functions J 1 & J2 respectively then an infinite resistance voltmeter detects
the electromotive force E, or if a low resistance ammeter is connected, a current flow I is
measured.

J1
A J2 J1 J2
I
B E
T1 T2 T1 T2

Experimentally, it has been found that the magnitude of E depends upon the materials as
well as the temperature Tl & T2. Now, the overall relation between EMF E and the
temperatures T 1 & T2 forms the basis for thermoelectric measurements and is called
seebeck effect. Thus in practical applications, a suitable device is incorporated to indicate
the EMF E or the flow of current I. For convenience of measurement and standardization,
one of the two functions is usually maintained at some known temperature. The measured
EMF E then indicates the temperature difference relative to the reference temperature,
such as ice point, which is very commonly used in practice.

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It may be noted that temperature Tl and T2 of functions 11 and J2 respectively are
slightly altered if the thermo-electric current is allowed to flow in the circuit. Heat is
generated at the cold junction and is absorbed from the hot junction thereby heating the cold
junction slightly and cooling the hot junction slightly. This phenomenon is termed peltiers
effect. If the thermocouple voltage is measured by means of potentiometer, no current flows
and peltier heating and cooling are not present. Further, these heating and cooling effects are
proportional to the current and are fortunately quite negligible in a thermocouple circuit,
which is practically a millivolt range circuit. In addition, the function EMF may be slightly
altered if a temperature gradient exists along either or both the materials. This is known as
Thomson effect. Again, the Thomson effect may be neglected in practical thermo-electric
circuits and potentiometer voltage measurements are not susceptible to this error as there is
no current flow in the circuit. The actual application of thermocouples of the measurements
requires consideration of the laws of thermo-electricity.

Law of intermediate temperatures states that the EMF generated in a thermocouple

with functions at temperatures Tl and T3 is equal to the sum of the EMFs generated by
similar thermocouples, one acting between temperatures T 1 and T2 the other between T2
and T3 when T2 lies between T 1 & T2.

T1 T2 T3

E1 E2

T1 T3

E3 E2
E3 = E1 + E2
Law Of Intermediate Temperature:
This law is useful in practice because it helps in giving a suitable correction in case a
reference function temperature other than O°C is employed. For example if a thermocouple is
calibrated for a reference function temperature of O°C and used with function temperature of
say 20°C, then the correction required for the observation would be the EMF produced by the
thermocouple between O°C and 20°C.

Law of intermediate metals the basic thermocouple loop consists of two dissimilar
metals A & B. If a third wire is introduced then three functions are formed B-C and C-A and
at the same temperature.

It may be noted that extension wires are needed when the measuring instrument is to
be placed at a considerable distance from the reference function. Maximum accuracy is
obtained when the leads are of the same material as the thermocouple element. However, this
approach is not economical while using expensive thermocouple materials. Further, a small
inaccuracy is still possible if the binding post of the instrument is made of say copper and two
binding posts are at different temperatures. Therefore, it is preferable to employ the system
shown in figure to keep the copper - iron and copper - constantan functions in the thermos
flask at O°C and provide binding posts of copper. This ensures maximum accuracy in the
thermocouple operation.

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 SIR C R REDDY COLLEGE OF ENGINEERING
Thermocouple Materials:
The choice of materials for thermocouples is governed by the following factors:

1. Ability to withstand the temperature at which they are used.

2. Immunity from contamination / oxidation etc. which ensures maintenance of the precise
thermo - electric properties with continuous use.
3. Linearity characteristics.

It may be noted that the relationship between thermo - electric EMF and the
difference between hot and cold function temperature is approximately of the parabolic form.

E = aT + bT2

A typical thermo - electric response of a copper - iron thermocouple is shown in fig. It

has a nearly linear range between OA, which is usable range of the thermocouple.

As is clear from fig. as the temperature difference increases the thermo EMF increases and
reaches a maximum at 285°C and after that it starts to fall. This feature of neutral
temperature is interesting but has a disadvantage in practical measurements. In the region
of the neutral temperature the thermocouple is extremely insensitive to the change in
temperature and there is even a possibility of ambiguity in the temperature reading.

Thermocouples can be broadly classified in two categories.

1. Base - metal thermocouple
2. Rare - metal thermocouple

Base-metal thermocouple use the combination of pure metals and alloys of iron,
copper and nickel and are used for temperature up to l450K. These are most commonly used
in practice as they are more sensitive, cheaper and have nearly linear characteristics. Their
chief limitation is the lower operating range because of their low melting point and
vulnerability to oxidation. On the other hand, rare-metal thermocouples use a combination of
pure metals and alloys of platinum for temperature up to 2000 K and tungsten, rhodium and
molybdenum for temperature up to 2900 K.

Controls:
1. Connect the Thermocouple to the back panel of the instrument
2. POWER ON: This facility supply of power to the instrument
3. MIN: Potentiometer provided to calibrate for min temperature.
4. MAX: Potentiometer provided to calibrate for MAX temperature
5. FUSE: Protect the instrument against internal short circuit rating 500 mA.
6. MAIN CABLE: 3 Pin 230v 50Hz cable.

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 SIR C R REDDY COLLEGE OF ENGINEERING
Operation / Procedure:
1. Connect the thermocouple to the back panel of the instrument.
2. Switch ON the power to the instrument
3. The display reads room temperature.
4. Fix the thermocouple to the tool tip.

Note the Temperature of tool tip using the digital temperature indicator.

Observations:

Room Temperature T1 Tool Tip Temperature Depteh of Cut

S.No 0 0
C C (mm)
1
2
3
4
5

Room Temperature T1 Tool Tip Temperature Speed

S.No 0 0
C C (RPM)
1
2
3
4
5

Room Temperature T1 Tool Tip Temperature Feed

S.No 0 0
C C (mm/REV)
1
2
3
4
5

Graphs To Be Drawn:
1. Tool tip temperature Vs Depth of cut
2. Tool tip temperature Vs Speed
3. Tool tip temperature Vs Feed

DEPARTMENT OF MECHANICAL ENGINEERING 16