Chapter 2
MECHANICS OF
METAL CUTTING
Prof. Dr. S. Engin KILI
MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II
Content
Terms and Definitions
Chip Formation
Cutting Forces and Force
Diagram
Shear Angle
Orthogonal Cutting
Geometry
Mathematical Models
Metal Removal Rate
Power Requirement
Examples
Photos from internet
sites.
MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II
Terms and Definitions
Machining : Removal
of material in the form
of chips from the
workpiece by shearing
with a sharp tool.
Resultant Cutting Motion
in Cylindrical Turning
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Terms and Definitions
Kalpakjian-Schmid,
2008
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Terms and Definitions
Orthogonal Cutting
Oblique Cutting
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Terms and Definitions
Oblique Cutting
(a)
MFGE 307
Schematic illustration of cutting with an
oblique tool. (b)
Top view, showing the
inclination angle, i.
(c)
Types of chips produced with different
inclination
angles.
THEORY
OF MANUFACTURING TECHNOLOGY
II
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Terms and Definitions
Orthogonal Cutting Analogy in Turning (for
0
=0
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Terms and Definitions
Relative Motion
between tool and
workpiece
Primary
motion
Secondary
motion
Cutting
motion
Feed
motion
Cutting
speed
Feed rate
Depth of cut
adjustment
Depth of cut
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Chip Formation
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Chip Formation
Shiny (burnished) surface on the
tool side of a continuous chip
produced in turning.
Basic types of chips produced in metal cutting
and their micrographs: (a) continuous chip with
narrow, straight primary shear zone; (b)
secondary shear zone at the tool-chip
interface; (c) continuous chip with built-up
edge;
(d)
serrated
(segmented
or
nonhomogeneous) chip; and (e) discontinuous
chip. Source: After M.C. Shaw, P.K. Wright, and
S. Kalpakjian.
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ME 303 - Section 05a
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Continuous Chip
Common in machining ductile materials
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Discontinuous Chip
Machining brittle
materials
Small rake angle
Large depth of cut
Machining ductile
materials at
low cutting speed
high feed
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Serrated Chip
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Continuous Chip with BUE
Occurs in machining
ductile materials with
high friction at toolchip interface
Chip welds to tool face
Destroys accuracy and
surface finish
Increases tool wear
Can be reduced by
decreasing depth of cut
increasing cutting
speed
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Cutting Forces
a0
ac
Fc: tangential (main) cutting
force
c u ttin g
to o l
Ft: thrust (feed) cutting force
Ff: frictional force on rake
Fs
Fc
Fn
Ft
Fr
Ff
c u ttin g
to o l
Fn: normal force on rake
Fs: shear force on shear plane
Fn : normal force on shear
s
plane
Fr: resultant force
shear angle
nnormal rake angle
MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II
Fn
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Cutting Forces
F 2 r Fc2 Ft 2 Fs2 Fn2s Fn2 F f2
tan( - n ) =
Ft
Fc
Fs Fc cos - Ft sin
Fns Fc sin Ft cos
F f Fc sin n + Ft cos n
Fn Fc cos n - Ft sin n
Ff
=
= tan
Fn
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Orthogonal Cutting Geometry
ac
a0
ls
sin cos n
ac
sin cos n
a0
ac
rc
a0
rc cos n
tan
1 rc sin n
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Theoretical Models
Only two of the simple thin shearzone models will be covered:
Ernst and Merchants model
Lee and Shaffers model
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Ernst and Merchant
Model
Common assumptions:
Sharp tool tip no
rubbing
or ploughing between tool
and
w.p.
Two dimensional
deformation
no side spread
Uniform stress distribution
on shear plane
Resultant force on shear
plane
equal and opposite to res.
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force at TECHNOLOGY
chip-tool interface.
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Main Assumption (EM Model)
Shear angle would take up such a value as to reduce
the work done in cutting to a minimum.
For given cutting conditions, work done in cutting is proportio
to Fc, it is necessary to develop an expression for Fc in terms o
and then to obtain the value of for which Fc is a minimum:
Fs Fr cos n
s Ac
Fs s As
sin
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Shear Angle (EM Model)
s shear strength of the work material on the shear plane
As area of the shear plane
A c cross - sectional area of the uncut chip
mean angle of friction
n normal rake angle
s Ac
1
Fc
0 to minimize Fc
sin cos n
Fc Fr cos n
2 n
s Ac cos n
2
Fc
sin cos n
Fr
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Work material is rigid plastic.
Elastic strain is negligible.
Behaviour of work material is
independent of the rate of
deformation.
Temperature effects are
neglected.
Inertia effects are neglected.
Uniform stress distribution at
the chip-tool interface.
Stress
Lee and Shaffers Model
Strain
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Main Assumptions (LS
Model)
A slip-line field is formed in the triangular
plastic zone extending from the shear plane
to the interface between the tool and the
chip where no deformation takes place
except for the transmission of forces from
tool-chip interface to shear plane and for the
material being stressed to its yield point.
All the deformation takes place in the plane
(Shear Plane) extending from the tool
cutting edge to the point of intersection of
the free surfaces of the work and the chip.
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Assumptions (Contd)
Maximum shear stress throughout the zone is s,
shear stress on the shear plane and two directions of
this max. shear stress are indicated by two orthogonal
sets of lines (slip lines).
Top surface of the triangular plastic zone then
becomes a free surface across which no stresses are
transmitted. Therefore between this surface and the
max. shear stress plane (shear plane) there is an
angle of /4.
Principal stresses act on the chip-tool interface
(secondary def. Zone) at angles and +/2.
Directions of max. shear stress lie at /4 to the dir. of
principal stress
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ME 303 - Section 05a
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Lee-Shaffer Theory
(Contd)
max
2
2 = 90o
Fr
45o
1
=
45o
45o
90o n
Hence,
n
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Metal Removal Rate
a
w = v.f.d
d
where,
w: metal removal rate
v: cutting speed
f
f
f: feed rate
cutting conditions
d: depth of cut
Ac: f.d = undeformed chip cross sectional
area
ac = f cos
Side Cutting Edge Angle
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Power Requirement
E: Energy required to remove unit volume of
chips
or
Resistance to cutting force
GJ
E 3 or GPa
m
GJ GN m GN
m 3 m 3 m 2 GPa
E Specific cutting energy Energy to remove unit volume of
chips
or
E Specific cutting pressure Force to produce chips with unit
MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II
cross
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sectional area
Power Requirement
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Power Requirement
Power required at the spindle:
E is a function of material property and the undeformed chip thickness
If Eo is the specific cutting energy for an undeformed chip thickness of 1
mm, then the specific cutting energy for a chip thickness ac :
E = Eo . (ac )
=>
so
ac
E = Power / Material Removal Rate
E = (Fc.v) / (v.f.d)
where ac = f . cos
E = (Fc . cos ) / (ac . d)
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Power Requirement
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Power Requirement
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ME 303 - Section 05a
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Power Requirement
EXAMPLE:
For an orthogonal cutting operation where v= 36 m/min f= 0.25 mm/rev it was found E
= 3.8 (W-sec/mm3) (m/min). If the power available at the spindle = 5 hp, find the
maximum metal removal rate and corresponding depth of cut. Note that 1 hp = 746 W.
Power 5 x746
w
E
3.8
mm 3
W
982
W
s
3
mm
N m
5 x746
Power
s 6216 N
F
36 m
v
60 s
mm 3
982
s
w
6.55mm
vf 36 x103 mm
x0.25mm
60 s
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Specific Cutting Energy
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Problem 1
In an orthogonal cutting test on mild steel, the following results
were obtained:
ac= 0.25 mm
a0= 0.75 mm
d = 2.5 mm
Fc = 900N
Ft = 450N
n = 100
a) Calculate the mean angle of friction on the tool rake
b) Calculate the cutting ratio
c) Calculate the shear angle
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Problem 2
For an orthogonal turning operation it was found that
power consumption of lathe when idle
= 325 W
power consumption of lathe when cutting = 2580 W
For the following conditions:
spindle speed, N = 124 rpm;
cutting speed, v = 24.5 m/min
depth of cut, d = 3.8 mm;
feed rate, f = 0.2 mm/rev
Find:
a) specific cutting energy of the work material,
b) torque at the spindle,
c) cutting force,
d) specific cutting energy for 1 mm undeformed chip thickness
assuming = 0.4.
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Problem 3
25 mm holes will be drilled on a steel workpiece, having a
hardness of Rc=45 {specific cutting energy, E = 77 W/(cm3/min)}
using an HSS twist drill at the following conditions:
cutting speed, v = 24.5 m/min
feed rate, f = 0.2mm/rev
Find:
a) the motor power if the efficiency of the transmission is 85%,
b) torque required.
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