Manufacturing Science 2

L1 : Introduction

Manufacturing Science 2

Introduction
Machining : Removal of excess material from work piece with harder
and pointed object (tool) due to relative motion between workpiece and tool
Speed
Depth of Cut

Tool
Chip
Cut surface

Workpiece
Relative Motion:
Motion responsible for cutting action
Motion responsible for feeding the uncut portion

L1 : Introduction

Primary Motion - Cutting Motion(CM)

Secondary Motion - Feed Motion (FM)

Manufacturing Science 2

Commonly used machining Processes

Turning

L1 : Introduction

Drilling

Manufacturing Science 2

Commonly used machining Processes

Turning
Primary Motion Cutting Motion(CM)

Rotation of work-piece

Secondary Motion Feed Motion (FM)

Linear movement of tool

L1 : Introduction

Drilling
Rotation of drill bit

Linear motion of drill bit

Manufacturing Science 2

Commonly used machining Processes

Turning
Shaper

Drilling
Planner

Primary Motion Cutting Motion(CM)

Linear movement of tool

(Intermittent)
Linear movement of tool

Secondary Motion Feed Motion (FM)

Linear movement of workpiece

(Intermittent)

Linear movement of workpiece

L1 : Introduction

Manufacturing Science 2

Commonly used machining Processes

Milling

Boring

Primary Motion Cutting Motion(CM)

Rotation of tool

Rotation of workpiece

Secondary Motion Feed Motion (FM)

Linear movement of workpiece

(continues)

Linear movement of tool

L1 : Introduction

Manufacturing Science 2

Concept of Directrix and Generatrix

Generatrix (G) : The line generated by the cutting motion
Directrix (D)
: The line generated by the feed motion

Eg.: Generation of cylindrical surface

Eg.: Interaction between G and D

L1 : Introduction

Manufacturing Science 2

Concept of Directrix and Generatrix

Generatrix (G) : The line generated by the cutting motion

Directrix (D)
: The line generated by the feed motion
Ways to generate Directrix and Generatrix
(a) Tracing (Tr) G and/or D is attained as a trace of path of a moving point

(b) Forming (F) G is simply the profile of the cutting edge

L1 : Introduction

Manufacturing Science 2

Concept of Directrix and Generatrix

Ways to generate Directrix and Generatrix (contd.)
(c) Tangent Tracing (TTr) : Directrix due to tangent to the series of paths traced by the

cutting edges

(d) Generation (G) : G or D is obtained as an envelope being tangent to the instantaneous

positions of a line or surface which is rolling on another surface.

L1 : Introduction

Manufacturing Science 2

Tool-workpiece interaction

Shaping
G-CM-T-Tr
D-FM-W-Tr
L1 : Introduction

Planning
G-CM-W-Tr
D-FM-T-Tr
Manufacturing Science 2

Tool-workpiece interaction
Q. Show the tool-work motions and the Generatrix and Directrix in drilling

G-CM-T-Tr
D-FM-T-Tr

L1 : Introduction

Manufacturing Science 2

Tool-workpiece interaction

G-x-T-F
D-(FM+CM)-(W+T)-TTr

Milling
L1 : Introduction

Boring
G-CM-W-Tr
D-FM-T-Tr
Manufacturing Science 2

Tool-workpiece interaction

G-x-T-F
D-(FM+CM)-(W+T)-TTr

Milling
L1 : Introduction

Manufacturing Science 2

Tool-workpiece interaction
How is Cutting and feed Motion expressed in turning, facing, shaping, drilling and milling

L1 : Introduction

Cutting Motion

Feed motion

mm/min (rpm)

mm/rev

mm/min (rpm)

mm/min

mm/min

mm/stroke

rpm

mm/rev

rpm

mm/min

Manufacturing Science 2

Mechanics of Machining Operation

Basic model of cutting operation

(2D, Orthogonal)

Tool-workpiece interaction

L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

Orthogonal : Relative velocity is perpendicular to the cutting edge

Oblique : Relative velocity is not perpendicular to the cutting edge

L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

Chip Formation :

Different types of chips of various shape, size, colour etc. are produced by machining
depending upon
type of cut, i.e., continuous (turning, boring etc.) or intermittent cut (milling)
work material (brittle or ductile etc.)
cutting tool geometry (rake, cutting angles etc.)
levels of the cutting velocity and feed (low, medium or high)
cutting fluid (type of fluid and method of application)
Mechanisms involved in chip formation are
Yielding generally for ductile materials
Brittle fracture generally for brittle material

L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

Chip Formation in ductile materials: Chips are produced by shearing ( Primary and
Secondary )
Primary Shearing : Shearing of workpiece marital along the plane of maximum
shear stress

Micrograph
showing
primary and secondary
shearing

L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

Chip Formation in ductile materials: Chips are produced by shearing ( Primary
and Secondary )
Secondary Shearing : at the interface of tool and chip

L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

Chip Formation in ductile materials: Chips are produced by shearing ( Primary and
Secondary )
Secondary Shearing : at the interface of tool and chip
Workpiece material adheres to tool surface,
sliding motion of chip on rack phase dose not occur
material first sticks and then shears

L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

Shear strain model (Piispanen model Applicable to ductile material)

Shear Angle
Rake angle
Chip thickness ratio r=t1/t2
Chip velocity Vc
Cutting speed V
Shearing velocity Vs
L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

Shear strain model (Piispanen model Applicable to ductile material)

Shear strain

L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

Chip Formation in brittle materials

L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

Chip Formation :

L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

Types of Chip
Continuous
Built-up edge (BUE)
Segmented
Discontinuous
Continuous chip :
Usually formed with ductile material, small uncut thickness, high cutting speed,
large rake angle, suitable cutting fluid
Good surface finish; steady cutting forces; undesirable in automated machinery
(CNC)
Built-up edge (BUE) :
Layers of Material from workpiece deposited on cutting edge of the tool
BUE are unstable, breaks when become larger
Part of BUE goes with chip and reaming deposited at the workpiece resulting in
rough surface
Higher the affinity of tool and workpiece material, the grater the tendency of
BUE formation
BUE occurs in alloys and not in pure metal ????
BUE is some time desirable ?????
L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

BUE

BUE hardness increases significantly

due to hardening

Strain hardening (work hardening) strengthening by cold-work (cold plastic deformation).

Cold plastic deformation causes increase of concentration of dislocations, which mutually entangle one
another, making further dislocation motion difficult and therefore resisting the deformation or increasing the
metal strength.
Grain size strengthening (hardening) strengthening by grain refining.
Grain boundaries serve as barriers to dislocations, raising the stress required to cause plastic deformation.
L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

BUE

Built-up edge (BUE) :

Continuous Chip
Without BUE

With BUE

work material ductile

Cutting velocity high Feed low
Rake angle positive and large
Cutting fluid both cooling and lubricating

work material ductile

cutting velocity medium
feed medium or large
cutting fluid inadequate or absent
L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

Jointed or segmented type or Serrated Chips
Chips with saw-tooth like appearance
Generally appears with metal with low thermal conductivity and strength that
decreases sharply with temperature eg Ti
Low temperature,
higher strength
lesser strain
High temperature,
low strength more
strain

Conditions:
- work material semi-ductile
- cutting velocity low to medium
- feed medium to large
- tool rake negative
- cutting fluid absent
L1 : Introduction

Manufacturing Science 2

Mechanics of Machining Operation

Discontinuous type
of irregular size and shape :
of regular size and shape :

- work material brittle like grey cast iron

- work material ductile but hard and work
hardenable
- feed large
- tool rake negative
- cutting fluid absent or inadequate

Discontinuous
Chip

Segmented
Chip

L1 : Introduction

Manufacturing Science 2

References:
Kalpakjian Chapter 20
Ghosh Mallik Chapter 4