You are on page 1of 33

MECHANICS OF METAL

CUTTING
Topics to be covered
Inroduction to Machining Technology
Cutting Models
Turning Forces
Merchants Circle
Power & Energies
Elements of Metal Cutting
Tool
Workpiece
Chip
Heat Generation Zones
(Dependent on sharpness
of tool)
(Dependent on )

(Dependent on |)

10%
30%
60%

Tool Terminology
Side relief
angle
Side cutting

edge angle

(SCEA)
Clearance or end
relief angle
Back
Rake

(BR),+
Side Rake
(SR), +
End Cutting

edge angle

(ECEA)
Nose
Radius
Turning
Cutting
edge
Facing
Cutting
edge
Cutting Geometry
Material Removal Rate
MRR = vfd
Roughing(R)
f = 0. 4 1. 25mm / rev
d = 2. 5 20mm
Finishing(F)
f = 0.125 0. 4mm / rev
d = 0.75 2.0mm
v
R
<< v
F
Cutting Models
ORTHOGONAL GEOMETRY OBLIQUE GEOMETRY
Tool
workpiece
Tool
workpiece
Assumptions
(Orthogonal Cutting Model)

The cutting edge is a straight line extending perpendicular
to the direction of motion, and it generates a plane surface
as the work moves past it.
The tool is perfectly sharp (no contact along the clearance
face).
The shearing surface is a plane extending upward from
the cutting edge.
The chip does not flow to either side
The depth of cut/chip thickness is constant uniform
relative velocity between work and tool
Continuous chip, no built-up-edge (BUE)

Orthogonal Cutting
r =
t
o
t
c
=
l
s
sin|
l
s
cos(| o)
tan | =
r coso
1 rsin o
=
AC
BD
=
AD+ DC
BD
= tan(| o) + cot |
F
t
F
C
F
r
DIRECTION OF ROTATION
WORKPIECE
CUTTING TOOL
DIRECTION OF FEED
Velocity of
Tool relative to
workpiece V
Longitudinal
'Thrust' Force (27%)
Radial
Force (6%)
Tangential 'Cutting' Force (67%)
Turning Forces For Orthogonal
Model
End view section 'A'-'A'
Note: For the 2D Orthogonal Mechanistic
Model we will ignore the radial component
F
t
'A'
'A'
c
F
F
L
F
C
F
r
DIRECTION OF ROTATION
WORKPIECE
CUTTING TOOL
DIRECTION OF FEED
Velocity of
Tool relative to
workpiece V
Longitudinal Force
Radial Force
Thrust Force
Tangential Force
'Cutting' Force
Facing Forces For Orthogonal Model
End view
Note: For the 2D Orthogonal Mechanistic
Model we will ignore the Longitudinal
component
'Turning' Terminology
N is the speed in rpm
D is the diameter of the
workpiece
f is the feed (linear
distance/rev)
d is the depth of cut
V is the surface speed
= tDN

Standard Terms
Beware, for turning: In the generalized
orthogonal model depth of cut (to) is f (the feed),
and width of cut (w) is d (the depth of cut)
N
| D
d mm
feed
(mm/rev)
Tool
Workpiece
rpm
Orthogonal Cutting Model
(Simple 2D mechanistic model)
Mechanism: Chips produced by the shearing process along the shear plane
o
t
0
|
+
Rake

Angle
Chip
Workpiece
Clearance Angle
Shear Angle
t
c
depth of cut
Chip thickness
Tool
Velocity V
tool
tool
Cutting Ratio
(or chip thicknes ratio)
As Sin| =
t
o
AB
and Cos(|-o) =
t
c
AB
Chip thickness ratio (r) =
t
0
t
c
=
sin|
cos(|o)
|
t
c
t
o
(|o)
A
B
Chip
Workpiece

Experimental Determination of
Cutting Ratio
Shear angle | may be obtained
either from photo-micrographs
or assume volume continuity
(no chip density change):

Since t
0
w
0
L
0
= t
c
w
c
L
c
and w
0
=w
c
(exp. evidence)
Cutting ratio , r =
t
0
t
c
=
L
c
L
0
i.e. Measure length of chips (easier than thickness)
w
t
L
0
0
0
w c
L
c
c
t
Shear Plane Length
and Angle |
Shear plane length AB =
t
0
sin|
Shear pl ane angl e (|) = Tan
-1 rcoso
1-rsi no
or make an assumption, such as | adjusts to minimize
cutting force:

| = 45
0
+ o/2 - |/2 (Merchant)
|
t
c
t
o
(|o)
A
B
Chip
tool
Workpiece
Velocities
(2D Orthogonal
Model)
Velocity Diagram
Frommass continuity: Vt
o
= V
c
t
c
From the Vel oci ty di agram:
V
s
= V
coso
cos(|o)
V
c
= Vr and V
c
= V
si n|
cos(|o)
(Chip relative

to workpiece)
V = Chip Velocity

(Chip relative to tool)
Tool
Workpiece
Chip
V
s V = Cutting Velocity
(Tool relative to

workpiece)
Shear Velocity
c
o
| o
90 |
|
V
s
V
c
V
Cutting Forces
(2D Orthogonal Cutting)
Free Body Diagram
Generally we know:
Tool geometry & type
Workpiece material

and we wish to know:
F = Cutting Force
F = Thrust Force
F = Friction Force
N = Normal Force
F = Shear Force
F = Force Normal

to Shear
c
t
s
n
Tool
Workpiece
Chip
Dynamometer
R
R
R
R
F
c
F
t
|
s
F
F
n
N
F
Force Circle Diagram
(Merchants Circle)
R
F
t
F
c
Tool
F
N
o
| o
|
o
o
F
s
|
| o
|
F
n
Results from
Force Circle Diagram
(Merchant's Circle)
Friction Force F = F
c
sino + F
t
coso
Normal Force N= F
c
coso - F
t
sino
Shear Force F
s
= F
c
cos| - F
t
sin|
= F/N and = tan| (typically 0.5 - 2.0)
Force Normal to Shear plane F
n
= F
c
sin| + F
t
cos|

Forces on the Cutting Tool
and the workpiece

Importance: Stiffness of tool holder, stiffness of machine, and
stiffness of workpiece must be sufficient to avoid significant
deflections (dimensional accuracy and surface finish)
Primary cause: Friction force of chip up rake face + Shearing
force along shear plane
Cutting speed does not effect tool forces much (friction forces
decrease slightly as velocity increases; static friction is the
greatest)
The greater the depth of cut the greater the forces on the tool
Using a coolant reduces the forces slightly but greatly
increases tool life
Stresses
On the Shear plane:



Normal Stress = o
s
= Normal Force / Area =
F
n
AB w
=
F
n
sin|
t
o
w
Shear Stress = t
s
= Shear Force / Area =
F
s
AB w
=
F
s
sin|
t
o
w
On the tool rake face:



o = Normal Force / Area =
N
t
c
w
(often assume t
c
= contact length)
t = Shear Force / Area =
F
t
c
w
Note: t
s
= t
y
= yield strength of the material in shear
Power
Power (or energy consumed per unit time) is the product of
force and velocity. Power at the cutting spindle:

Power is dissipated mainly in the shear zone and on the rake
face:



Actual Motor Power requirements will depend on machine
efficiency E (%):


Cutting Power P
c
= F
c
V
Power for Shearing P
s
= F
s
V
s
Friction Power P
f
= FV
c
Motor Power Required =
P
c
E
x 100
Material Removal Rate (MRR)
Material Removal Rate (MRR) =
Volume Removed
Time
Volume Removed = Lwt
o
Time to move a distance L = L/V
Therefore, MRR=
Lwt
o
L/V
= Vwt
o
MRR = Cutting velocity x width of cut x depth of cut
Specific Cutting Energy
(or Unit Power)
Energy required to remove a unit volume of material (often quoted as
a function of workpiece material, tool and process:
U
t
=
Energy
Volume Removed
=
Energy per unit time
Volume Removed per unit time
Specific Energy for shearing U
s
=
F
s
V
s
Vwt
o
Specific Energy for friction U
f
=
FV
c
Vwt
o
=
Fr
wt
o
U
t
=
Cutting Power (P
c
)
Material Removal Rate (MRR)
=
F
c
V
Vwt
o
=
F
c
wt
o
Specific Cutting Energy
Decomposition


1. Shear Energy/unit volume (Us)
(required for deformation in shear zone)

2. Friction Energy/unit volume (Uf)
(expended as chip slides along rake face)

3. Chip curl energy/unit volume (Uc)
(expended in curling the chip)

4. Kinetic Energy/unit volume (Um)
(required to accelerate chip)
U
t
= U
s
+ U
f
+U
c
+U
m

Specific Cutting Energy
Relationship to Shear strength of Material
SHEAR ENERGY / UNIT VOLUME

Specific Energy for shearing U
s
=
F
s
V
s
Vwt
o
FRICTION ENERGY / UNIT VOLUME
Specific Energy for friction U
f
=
FV
c
Vwt
o
=
Fr
wt
o
=
F
wt
c
= t
APPROXIMATE TOTAL SPECIFIC CUTTING ENERGY
U
t
= U
s
+ U
f
= t
s
+ t = t
y
(1+ )
U
s
=
t
s
coso
si n| cos(|o)
= t
s
.
Relation between Pressure and
Cutting velocity
Effect of Rake angle on Cutting
Force
Average Unit Horsepower Values
of Energy per unit volume
Typical Orthogonal Model
Violations
Geometry and form Violations (i.e. non zero angles of
inclination, not sharp - radiused end)

Shear takes place over a volume (not a line or plane)

Cutting is never a purely continuous process (cracks develop
in chip; material not homogeneous)

'Size Effect' - larger stresses are required to produce
deformation when the chip thickness is small (statistical
probability of imperfection in the shear zone)

BUE - some workpiece material 'welds' to the tool face
(cyclic in nature)

You might also like