Metal

Machining

ME 482 - Manufacturing Systems

Objectives
Introduce cutting terminology and principles
Review modern machining technologies and new methods
(papers)
Introduce cutting parameters
Develop cutting models
Analyze a cutting example

ME 482 - Manufacturing Systems

Machining types
Turning
Drilling
Milling
Shaping
Planing
Broaching
ME 482 - Manufacturing Systems

Machining tools
Single point

Multiple point

ME 482 - Manufacturing Systems

Machining tool materials

Most modern cutting tool materials are a matrix of
materials designed to be very hard. These materials will be
covered in the next chapter.

ME 482 - Manufacturing Systems

Machining surface finish

ME 482 - Manufacturing Systems

Machining terminology
Speed surface cutting speed (v)
Feed advance of tool through the part (f)
Depth of cut depth of tool into part (d)
Rake face tools leading edge
Rake angle slant angle of tools
leading edge ()

Flank following edge of cutting tool

Relief angle angle of tools following edge above part surface
ME 482 - Manufacturing Systems

Machining terminology (cont.)

ls

Chip thickness thickness of machined chip (tc )

Orthogonal model

Depth of cut = to
Shear plane length measured along shear plane chip (ls )
Chip width (not shown) width of machined chip (w )
Shear angle angle of shearing surface measured from tool direction ()
ME 482 - Manufacturing Systems

Cutting conditions
Note: - Primary cutting due to speed
- Lateral motion of tool is feed
- Tool penetration is depth of cut
The three together form the material removal rate (MRR):
MRR = v f d
with units of (in/min)(in/rev)(in) = in3/min/rev

(or vol/min-rev)

Types of cuts:
Roughing:

feeds of 0.015 0.05 in/rev

depths of 0.1 0.75 in

Finishing:

feeds of 0.005 0.015 in/rev

depths of 0.03 0.075 in

ME 482 - Manufacturing Systems

Cutting geometry
Chip thickness ratio = r = to / tc

From the shear plane geometry:

r = ls sin/[ls cos(-)]

which can be arranged to get

tan = r cos /[1 r sin]
ME 482 - Manufacturing Systems

Obviously, the
assumed failure
mode is shearing of
the work along the
shear plane.

Cutting geometry
Note from the triangles in (c) that the shear strain () can be
estimated as
= AC/BD = (DC + AD)/BD = tan(- ) + cot

Thus, if know
r and can
determine ,
and given
and , can
determine .
ME 482 - Manufacturing Systems

Cutting forces
Since R = R = R, we can get the force balance equations:
F = Fc sin + Ft cos

F = friction force; N = normal to chip force

N = Fc cos - Ft sin

Fc = cutting force; Ft = thrust force

Fs = Fc cos - Ft sin Fs = shear force; Fn = normal to shear plane force

Fn = Fc sin + Ft cos

Forces
Forces are
are presented
presented as
as function
function of
of
F
Fcc and
and Ftt because
because these
these can
can be
be
measured.
measured.

Friction angle =
tan= = F/N
Shear plane stress:
= Fs/As
where
As = to w/sin

ME 482 - Manufacturing Systems

Cutting forces given shear strength

Letting S = shear strength, we can derive the following
equations for the cutting and thrust forces*:

Fs = S As
Fc = Fs cos (cos (
Ft = Fs sin (cos (
* The other forces can be determined from the equations on the previous
slide.
ME 482 - Manufacturing Systems

Merchant equations
The
reln
is a function of
Combining the equations from
theMerchant
previous
slides:

= (Fc cos - Ft

and . Where did these variables

sin t
Merchant eqn
ow/sin
come
from?

The most likely shear angle will

minimize
the energy. Applying
Answer
- Although the Merchant
d/d = 0 gives:
eqn is not shown as a direct function
= 45 +
What does the Merchant
- increase
- increase

of
the
and , these enter from
Merchant reln
equations for Fcc and Ftt from the
previous
slide!
relation
indicate?

If we increase the shear angle, we

in friction angle decreases
decreaseshear
the toolangle
force and power
requirements!
in rake angle increases shear
angle

ME 482 - Manufacturing Systems

Cutting models
The orthogonal model for turning approximates the complex
shearing process:
to = feed (f)
w = depth of cut (d)

ME 482 - Manufacturing Systems

Cutting power
Power is force times speed:
P = Fc v

(ft-lb/min)

The cutting horsepower is

hpc = Fc v/33,000

(hp)

The unit horsepower is

hpu = hpc/MRR

units?

Due to efficiency losses (E about 90%), the gross hp is

hpg = hpc/E
ME 482 - Manufacturing Systems

Cutting energy
Specific energy is
U = Fc v/(v tow) = Fc /(tow)

(in-lb/in3)

The table shown contains power and specific energy ratings for several work materials
at a chip thickness of 0.01 in. For other chip thicknesses, apply the figure to get a
correction factor multiply U by correction factor for thickness different than 0.01).

ME 482 - Manufacturing Systems

Machining example
In orthogonal machining the tool has rake angle 10 , chip thickness before
cut is to = 0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting
and thrust forces are measured at Fc = 350 lb and Ft = 285 lb while at a
cutting speed of 200 ft/min. Determine the machining shear strain, shear
stress, and cutting horsepower.
Solution (shear strain):
Determine r = 0.02/0.045 = 0.444
Determine shear plane angle from tan = r cos /[1 r sin]
tan = 0.444 cos /[1 0.444 sin] => = 25.4
Now calculate shear strain from = tan(-) + cot
= tan(25.4 - 10) + cot 25.4 = 2.386 in/in
ME 482 - Manufacturing Systems

answer!

Machining example (cont.)

In orthogonal machining the tool has rake angle 10 , chip thickness before
cut is to = 0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting
and thrust forces are measured at Fc = 350 lb and Ft = 285 lb while at a
cutting speed of 200 ft/min. Determine the machining shear strain, shear
stress, and cutting horsepower.
Solution (shear stress):
Determine shear force from Fs = Fc cos - Ft sin
Fs = 350 cos 25.4 - 285 sin 25.4 = 194 lb
Determine shear plane area from As = to w/sin
As = (0.02) (0.125)/sin= 0.00583 in2
The shear stress is
ME 482 - Manufacturing Systems

Machining example (cont.)

In orthogonal machining the tool has rake angle 10 , chip thickness before
cut is to = 0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting
and thrust forces are measured at Fc = 350 lb and Ft = 285 lb while at a
cutting speed of 200 ft/min. Determine the machining shear strain, shear
stress, and cutting horsepower.

Solution (cutting horsepower):

Determine cutting hp from hpc = Fc v/33,000
hpc = (350) (200)/33,000 = 2.12 hp
ME 482 - Manufacturing Systems

answer!

Cutting temperatures
In machining 98% of the cutting energy is converted into heat. This
energy flows into the work part, chip, and tool. Cook determined an
experimental equation for predicting the temperature rise at the
tool-chip interface during machining:

Example in text calculates

T = 0.4 U (v to/K) /( c)
T = 936 total tool
where
temperature, given v =
T = mean temperature rise (F) 200 ft/min, c = 120 in-lb/
U = specific energy (in-lb/in3)
(in3- F) and K = 0.125
v = cutting speed (in/s)
in2/s
0.333

to = chip thickness before cut (in)

c= volumetric specific heat of the work material (in-lb/(in 3-F))
K = thermal diffusivity of the work material (in 2/s)

Note - To get total temperature at tool-chip interface, must add in ambient

ME 482 - Manufacturing Systems

Cutters
Toroid

ME 482 - Manufacturing Systems

Cutters

ME 482 - Manufacturing Systems

Machining

What did we learn?

ME 482 - Manufacturing Systems