LECTURE-09

THEORY OF METAL CUTTING

- Mechanics of Metal Cuttin
NI!HIL R" #HAR$ %h" #"
DEPARTMENT OF INDUSTRIAL & PRODUCTION
ENGINEERING
BUET
P
x
P
y
P
z
&'() #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
Mechanics of Metal Cuttin
The force acting on a cutting too !uring the "roce## of $eta
cutting are the fun!a$enta i$"ortance in the !e#ign of cutting
too#% The !eter$ination of cutting force# nece##ar& for
!efor$ation the 'or( $ateria at the #hear )one i# e##entia for
#e*era i$"ortant re+uire$ent#,

to e#ti$ate the "o'er re+uire$ent# of a $achine too

to e#ti$ate the #training action# that $u#t -e re#i#te! -& the

$achine too co$"onent#. -earing#. /ig# an! fi0ture#

to e*auate the roe of *ariou# "ara$eter# in cutting force#

to e*auate the "erfor$ance of an& ne' 'or( $ateria. too

$ateria. en*iron$ent. techni+ue# etc% 'ith re#"ect to $achina-iit&
1cutting force#2
&'(/ #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
The force #&#te$ in the genera ca#e of con*entiona turning "roce## i#
#ho'n in the foo'ing Fiu+e"
P
x
P
y
P
z
P
z
P
x
P
y
P
xy
R
P
0
3 fee- fo+ce in the !irection of the too tra*e
P
&
3 th+ust fo+ce in the !irection "er"en!icuar to the "ro!uce! #urface
P
)
3 cuttin fo+ce or ,ain fo+ce acting in the !irection of the cutting *eocit&%
&'(0 #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
P
z
P
x
P
y
P
xy
X
Y

P
xy
R
Z
XY
R
.......[2] .......... cos P P
] ........[1 .......... sin P P
xy y
xy x

&'(1 #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in

Se*era force# can -e !efine! reati*e to the orthogona cutting $o!e%
Ba#e! on the#e force#. #hear #tre##. coefficient of friction. an! certain
other reation#hi"# can -e !efine!%
R
P
s
R
2
Workpiece
Tool
Chip

P
z
P
n
P
xy
N
F
R
1
&'(2 #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
Me+chant Ci+cle #ia+a, 3MC#4
The foo'ing reation#hi"# #ugge#t a circe re"re#entation of force# a#
!one -& Me+chant an! in!icate! in the foo'ing Fiu+e%
P
xy
Workpiece
P
z
P
n
P
s
F
N
R

o

-
o
Tool
Chip
.[7] .......... .......... cos P sin P P
..[6] .......... .......... sin P cos P P
] 5 [ .......... .......... sin P cos P N
] 4 .[ .......... .......... cos P sin P F
] 3 .......[
xy
P
z
P
n
P
s
P N F R
xy z n
xy z s
o xy o z
o xy o z

+


+
+ + +
.....[8] tan
sin P cos P
cos P sin P
N
F

[5] an [4] !"#ation F$o%

o xy o z
o xy o z

+

4here.
5 3 (inetic coefficient of friction
& $ean ange of friction at the ra(e #urface
&'(5 #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
Fro$ the geo$etr& of force reation# of MCD circe
P
xy
Workpiece
P
z
P
n
P
s
F
N
R

o

-
o
Tool
Chip
] 11 [ ..........
' ( cos
' ( cos
P P
[1)] an [*] !"#ation F$on
..[1)] '......... cos( R P
.......[*] '......... cos( R P
o
)
s z
) s
) z
1
]
1

+

Ba#e! on the #hear force. the #hear #tre##
1+
s
2 'hich act# aong the #hear "ane
-et'een the 'or( an! the chi" i#,
] 12 [ ..........
t ,
sin P
+
sin
t ,
-.an/ s0/a$ t0/ o1 a$/a 2s 30/$/ 4
2
P
+
o
s
s
o
s
s
s

&'(' #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
] .......[14
' cos( sin
' sin(
t , + P
,i%i.a$.y4
.[13] ..........
' cos( sin
' cos(
t , + P
[12] [11]an !"#ation F$o%
o
)
) s xy
o
)
) s z
1
]
1

1
]
1

P
xy
Workpiece
P
z
P
n
P
s
F
N
R

o

-
o
Tool
Chip
In $eta cutting one of the $ain "ro-e$ i# to
e*auate the cutting force# P
)
an! P
0&
fro$ the
gi*en cutting con!ition# an! initia "ro"ertie# of
'or( $ateria an! it i# nece##ar& to !eter$ine +
s
.
6 an! 7 -& #uita-e reation#hi"#%
&'(9 #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
Ea+nest-Me+chant Theo+6
Ern#t an! Merchant e0ten!e! their ana&#i# an! #tu!ie! the reation#hi" -et'een the #hear
ange an! the cutting con!ition#% The& #ugge#te! that the #hear ange a'a&# ta(e# the *aue
that re!uce# the tota energ& con#u$e! in cutting to a $ini$u$% Becau#e the tota 'or( !one
in cutting i# !e"en!ent u"on an! i# a !irect function of the co$"onent P
)
of the cutting force.
the& !e*eo"e! an e0"re##ion for P
)
in ter$# of 6 an! the con#tant "ro"ertie# of the 'or("iece
$ateria% Con!ition for $a0i$u$ cutting force 1P
)
2 fro$ E+uation 89:;
{ }
...[16] .......... cot t , + 2 P
[15] an [13] !"#ation 5o%6inin7
] 15 ........[ ..........
2
8
cos ) ' cos( o$ )4 ' sin( sin ' cos( cos
)
cos( sin
' sin( sin ' cos( cos
' cos( t , +
)
' cos(
' cos(
.
sin
t , +

P
o$4 )4

P
) s z
) ) )
2
)
) )
) ) s
o
) ) s z z

+

,
_

+ + + +

1
]
1

+
+ +

1
]
1
+

2
0

&'(&0 #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in

Me+chant Theo+6
Merchant $o!ifie! the reation#hi" !eri*e! -& Earne#t<Merchant. -&
a##u$ing that the #hear #tre## aong the #hear "ane *arie# inear& 'ith
nor$a #tre## 1=
n
2% It i# gi*en a# 1fro$ the foo'ing Figure2%

0
7
[ ]
] 2) ...[ .......... ..........
'
)
tan( 9 1
)
+
s
+
[1*] an [17] !"ation F$o%
[1*] .......... .......... '
)
tan(
s
+
n
:
'
)
tan(
s
2
s
P
s
2
n
P
'
)
tan(
s
P
n
P
......[18] .......... '
)
Rsin(
n
P an '
)
cos( R
s
P
;5< o1 $/.ations 1o$c/ o1 7/o%/t$y t0/ F$o%
] 17 ......[ ..........
n
: 9
)
+
s
+
+

+
+
+
+ +
+
&'(&& #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
Co$-ining E+uation 89:; an! 8>?;
{ }
{ }
[ ]
[ ] ] 23 [ .......... ' tan(c cot t
)
,
s
+
z
P
[22] an [21] !"#ation F$o%
] 22 .......[ .......... ..........
)
85 to
)
8) c (9'
1
cot
)
2
9 '
)
cot(2
) '
)
sin(2 9 '
)
cos(2
)
' sin( sin ' cos( sin
' cos( sin ' sin( cos
' sin( sin ' cos( cos
' cos(
)
' tan( 1 ' cos( sin
' cos(
o$ )4

z
P
[21] !"#ation 1$o% (Pz' 1o$c/ c#ttin7 %axi%#% 1o$ 5onition
] 21 .....[ ..........
' tan( 1 ' cos( sin
' cos(
2
) )
) )
) )
) )
) )
) )
) )
) )
+

+
+
+ +

+ +
1
]
1

+ +
+ +

+ +

+ +

k
k k
t S
or
k
t S
d
d
d
dP
k
t S
P
s
o z
o
z
&'(&) #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
Lee an- 8haffe+ Theo+6
Accor!ing to thi# theor& the #hear occur# on a #inge "ane% So for a
cutting "roce## accor!ing to thi# theor&. the foo'ing are #u""o#e! to
ho! goo!,

The $ateria ahea! of the cutting too -eha*e! a# i!ea "a#tic $ateria

The chi" !oe# not get har!ene!

The chi" an! "arent 'or( $ateria are #e"arate! -& a #hear "ane%
( )
( ) ..[25] .......... 1 tan = t , + P
tan =
cos
sin =
tan
1
cot
>0/$/4
....[25] .......... 1 cot t , + P
[24] an [13] !"#ation F$o%
..[24] .......... ..........
4
8

) ) s z
o
o
o
) s z
)
+

+
+
Lee an! Shaffer !eri*e! the foo'ing reation#hi" a#,
&'(&/ #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
The+,al As*ect of Chi* Fo+,ation
Machining i# inherent& characteri)e! -& generation of heat an! high
cutting te$"erature% At #uch ee*ate! te$"erature the cutting too if
not enough hot har! $a& o#e their for$ #ta-iit& +uic(& or 'ear out
ra"i!& re#uting in increa#e! cutting force#. !i$en#iona inaccurac& of
the "ro!uct an! #horter too ife% The $agnitu!e of thi# cutting
te$"erature increa#e#. though in !ifferent !egree. 'ith the increa#e of
cutting *eocit&. fee! an! !e"th of cut. a# a re#ut. high "ro!uction
$achining i# con#traine! -& ri#e in te$"erature% Thi# "ro-e$ increa#e#
further 'ith the increa#e in #trength an! har!ne## of the 'or( $ateria%
@no'e!ge of the cutting te$"erature ri#e in cutting i# i$"ortant.
-ecau#e increa#e# in te$"erature,

a!*er#e& affect the #trength. har!ne## an! 'ear re#i#tance of the cutting
too

cau#e !i$en#iona change# in the "art -eing $achine!. $a(ing contro of

!i$en#iona accurac& !ifficut an!

can in!uce ther$a !a$age to the $achine! #urface. a!*er#e& affecting it#
"ro"ertie# an! #er*ice ife%
&'(&0 #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
In a!!ition. the $achine too it#ef $a& -e
#u-/ecte! to te$"erature gra!ient#. cau#ing
!i#tortion of the $achine% The $ain #ource# of
heat in $eta cutting are #ho'n in the foo'ing
Fiu+e% The#e three !i#tinct heat #ource# are,

the #hear )one 1+

9
2. 'here the $ain "a#tic
!efor$ation ta(e# "ace

the chi"<too interface )one 1+

>
2. 'here #econ!ar&
"a#tic !efor$ation !ue to friction -et'een the
heate! chi" an! the too ta(e# "ace

the 'or( too interface 1+

:
2. at fan(# 'here
frictiona ru--ing occur#%
9o+7*iece Tool
Chi*
q
1
q
2
q
3
1
1
1
]
1

+ +
+

1
]
1

ai$ 7 s#$$o#nin t0/ into $aiat/ 0/at o1

2%o#nt 3o$9-i/c/ t0/ into -assin7 0/at o1 2%o#nt too. c#ttin7
in t0/ $/%ainin7 0/at o1 2%o#nt c0i-s in a3ay 0/at o1 2%o#nt
7/n/$at/ 0/at o1
a%o#nt ?ota.
@ as 3$itt/n 6/ can 1o$%ation c0i- in 6a.anc/ 0/at ?0/
&'(&1 #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
Aariou# #tu!ie# ha*e -een $a!e of te$"erature# in cutting. -a#e! on
heat tran#fer an! !i$en#iona ana&#i#. u#ing e0"eri$enta !ata% A
#i$"e an! a""ro0i$ate e0"re##ion for the $ean te$"erature for
orthogona cutting i#
333 .. )
4 . )

,
_

K
t V
C
U
T
c

thermal diffusivity (ratio of thermal conductivity to volumetric specific heat) of the

workpiece material (m
2
/sec).
= K
volumetric specific heat of the workpiece (J/mm
2
-C) = pC
depth of cut (mm) = t
cuttin velocity (m/sec) = !
c
specific enery in the operation ("-m/mm
#
) = $
mean temperature rise at the tool-chip interface (
o
C) = %
where&
&'(&2 #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
E:e+cise
The !&na$o$eter recor!e! the foo'ing. fee! force >?? (g. cutting force
:?? (g% The ra(e ange of the too u#e! 'a# 9?
o
% The chi" thic(ne## ratio
?%:B% Fin!

Shear ange 162

Shear force 1P
#
2

Co<efficient of friction at the chi"<too interface 152 an! the friction ange 12

Co$"re##i*e force at the #hear "ane 1P

n
2%
A #ea$e## tu-e :c$ out#i!e !ia$eter i# re!uce! in ength on a athe 'ith
the he" of a #inge "oint cutting too% The cutting #"ee! i# C? $D$in. the
!e"th of cut i# ?%9>B$$% The ength of continuou# chi"#. for one re*oution
of the tu-e. on $ea#ure$ent co$e# to -e 9E%EEc$% The cutting force i# >??
(g an! the fee! force i# EB (g% the ra(e ange of the too i# :B
o
%Cacuate.

Co<efficient of friction

Chi" thic(ne## ratio

Shear "ane ange

Aeocit& of the chi" aong the too face

Aeocit& of #hear aong the #hear "ane

&'(&5 #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
During the $achining of AISI<9?>B #tee. 'ith ?<9?<F<F<G<H?<9 1$$2
ORS #ha"e! too the foo'ing o-#er*ation# 'ere ta(en,

Fee! ?%B? $$Dre*

De"th of cut 3 >%? $$

Cutting #"ee! 3 C? $D$in

The #hear ange 3 >?

o

The "o'er con#u$e! 'hie $achining3 :(4

The "o'er con#u$e! 'hie running i!e 3 ?%B? (4

Cacuate,

The #hear force

Chi" thic(ne## ratio

Nor$a "re##ure on the chi"

Chi" thic(ne##
&'(&' #e*a+t,ent of In-ust+ial . %+o-uction Eninee+in
An6 ;uestions o+
co,,ents<