LECTURE-09 THEORY OF METAL CUTTING - Mechanics of Metal Cutting

Px Py Pz
NIKHIL R. DHAR, Ph. D.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING BUET
Mechanics of Metal Cutting
The force acting on a cutting tool during the process of metal cutting are the f
undamental importance in the design of cutting tools. The determination of cutti
ng forces necessary for deformation the work material at the shear zone is essen
tial for several important requirements:

to estimate the power requirements of a machine tool to estimate the straining a

ctions that must be resisted by the machine tool components, bearings, jigs and
fixtures to evaluate the role of various parameters in cutting forces to evaluat
e the performance of any new work material, tool material, environment, techniqu
es etc. with respect to machinability (cutting forces)
Department of Industrial & Production Engineering
18/2
The force system in the general case of conventional turning process is shown in
the following Figure. Px Py Pxy
Px Py Pz
Pz
R
Px = feed force in the direction of the tool travel Py = thrust force in the dir
ection perpendicular to the produced surface Pz = cutting force or main force ac
ting in the direction of the cutting velocity.
Department of Industrial & Production Engineering 18/3
R XY Z Pz Pxy X
φ Pxy Py
Y
R
Px = Pxy sinϕ ..................[1] Py = Pxy cosϕ .................[2]
Px
Πo
Department of Industrial & roduction Engineering
18/4
Several forces can be defined relative to the orthogonal cutting model. Based on
these forces, shear stress, coefficient of friction, and certain other relation
ships can be defined.
n R2
β Ps Pxy
R R1 F
Chip
γ N Pz
Workpiece
Department o
Industrial & Production Enineerin
Tool
18/5
Merchant Circle Diaram (MCD) 
The
ollowin relationships suest a circle representation o

orces as done y
Merchant and indicated in the
ollowin Fiure.
R = F + N = P + P = P + P .......[3] s n z xy F = Pz sin γ o + Pxy cos γ o .....
................[4] N = Pz cos γ o − Pxy sin γ o ....................[5] Ps = Pz
cos β − Pxy sin β ......................[6] Pn = Pz sin β + Pxy cos β .........
............[7]
N F η R
Pxy Pn Pz β
η-γo
Ps C ip
From Equation [4] and [5] F Pz sinγ o + Pxy cosγ o μ= = = tanη .....[8] N Pz cos
γo − xy sinγ o 
W ere, μ = kinetic coefficient of friction η = mean anle of friction at t e rak
e surface
Department of Industrial & Production Enineerin
γo
γo
Tool
Workpiece
18/6
 
From t e eometry of force relations of MCD circle
Pz = R cos(η − γ 0 )................[9] Ps = R cos(β + η − γ 0 )...........[10]
Fron Equation [9] and [10] cos (η − γ 0 ) Pz = Ps ..........[11] cos (β +
η − γ o )      
Based
 on t e s ear force,
 t e s ear stress (τs) which ac s along he shear plane
be ween he work and he chip is: η N F R Pxy Pn Pz β
η-γo
Ps C ip
γo
τs = τs =
 
Ps S , where As = area of he shear plane = o As sinβ Ps sinβ ..........[12] S
o t
Tool
γo
Workpiece
18/7
Department of Industrial & Production Enineerin
 
From Equation [11]and [12] cos(η − γ 0 ) Pz = τ s S0 ...........[13]
 sin
β cos(β + η − γ o ) Similarly, sin(η − γ 0 ) Pxy = τ s S0 .......[14] s
inβ cos(β + η − γ o )
N F
Pxy η R Pn Pz β
η-γo
Ps C ip
γo   
In metal cuttin 
  one of t emain pro lem is to evaluate t e cuttin forces Pz an
d Pxy from t e iven cuttin conditions and initial
 properties
 of work material
and it is necessary to determine τs, β and η y suita le relations ips.
γo
Tool
Workpiece
18/8
Department of Industrial & Production Enineerin
  
Earnest-Merc ant
 T eory    
Ernst
 and Merc ant extended
 t eir analysis and studied t e relations
  ip etween

t e s ear anle 
 and t e cuttin conditions.
 T ey suested t at t e s ear anle
always takes t evalue t at reduces t e total enery consumed in cuttin to a mi
nimum. Because  is dependent upon and is a direct
 t e total work done in cuttin
 
function of t e component Pz of t e cuttin force, t ey developed an expression
for Pz in terms of β and t e constant properties of t e workpiece material. Cond
ition for maximum cuttin force (Pz) from Equation [13]

dPz dP d τ s S0 cos(η − γ 0 ) = 0, or, z = . sinβ cos(β + η − γ ) = 0 dβ
dβ dβ o

cosβ cos(β + η − γ 0 ) − sinβ sin(β + η − γ 0 ) τ s S0 cos(η − γ 0 ) =0 2
{ sinβ cos(β + η − γ 0 } π cosβ cos(β + η − γ 0 ) − sinβ sin(β + η − γ 0 ) =
0, or cos(β
 + β + η − γ 0 ) = 0 = cos 2 π η γ0 β=  − + ..................[15]
4 2 2 Com inin Equation [13] and [15] Pz = 2 τ s S0 co β .............[16]
Deartment of Industrial & Production Enineerin 18/9
  
Mercant T eory        
Merc
 ant  i derived y Earnest Merc ant, y assumin t at
 modified t e relations

t e s ear stress alon t e s ear lane varies linearly wit normal stress (σn).
It i  given a  (from the following Figure).
τ = τ + k σ ................[17]  0 n From the geometry of force relation  of M
CD P = Rco (β + η − γ ) and P = Rsin(β + η − γ ) ................[18] s0 n 0 τ
s P = P an(β + η − γ ) n s 0 P P n = s tan(β + η − γ ) 0 A A s s σ = τ an(β +
η − γ ) ....................[19] n s 0 From Eqation [17] and [19] τ 0 τ = ......
.................[20] s 1 − k an(β + η − γ ) 0
k
τ0 σn
[
]
Department of Indu trial & Production Engineering
18/10
  
Com ining Equation [13] and [20] τ o S 0 cos(η − γ 0 ) Pz = ...............[ 2
1] sin β cos( β + η − γ 0 ) {1 − k tan( β + η − γ 0 )} Condition for maximum cut
tin force (Pz) from Equation [21] dP τ o S 0 cos(η − γ 0 ) z = 0, or dPz = d
=0 dβ dβ dβ sin β cos( β + η − γ 0 ) {1 − k tan( β + η − γ 0 )} 
cos β cos( β + η − γ 0 ) − sin β sin( β + η − γ 0 ) − τ s S 0 cos(η − γ 0 )
k cos β sin( β + η − γ 0 ) − k sin β cos( β + η − γ 0 ) = 0 or [ sin β cos( β
+ η − γ 0 ) − k sin β sin( β + η − γ 0 )] 2 cos(2β + η − γ ) − k sin(2β + η − γ
) = 0 0 0 cot(2β + η − γ ) = k 0 2β + η − γ = cot − 1(k) = c ≅ 800 to
 850......
.....................[22] 0 From Equation [21] and [22] P = τ S [ co β + tan(c
− β) ]..........[ 23] z  0
Department of Indu trial & Production Engineering 18/11
Lee and Shaffer Theory
According to thi  theory the hear occur  on a ingle plane. So for a cutting pr
oce  according to thi  theory, the following are uppo ed to hold good:


The material ahead of the cutting tool ehaved a  ideal pla tic materialThe chi
p doe  not get hardened The chip and parent work material are eparated y a he
ar plane.
Lee and Shaffer derived the following relation hip a : π β + η − γ 0 = .........
.............[24] 4 From Equation [13] and [24]
 
Pz = τ s S0 ( co β + 1)..............[25] Where,
cot β =
 
Pz = τ s S0 ( ξ − anγ 0 + 1)............[25]
1 ξ − in γ o = ≅ ξ − tan γ o tan β cos γ o
18/12
Deartment of Industrial & Production Enineerin
  
T ermal
 Asect of C i Formation
    
Mac inin is in erently c aracterized yeneration of eat and i cuttin  tem
erature. At suc elevated temerature t e cuttin tool if not enou ot ard m
 
ay lose t eir form sta ility quickly or wear  out raidly resultin

 in increased

 
cuttin forces,dimensional inaccuracy of t e roduct
    and
 s orter tool life.

T e
ma nitude of t is cuttin tem erature increases, t ou in different de ree, wi
t of cut, as a result, i r
t t e increase of cuttin velocity, feed and de
oduction macinin  is constrained y rise in temerature. Tis rolem increases
    
furt erwit t e increase in strent and ardness of t e work  material. Knowle
    
d e of t e cuttin tem erature rise in cuttin is im ortant, ecause increases i
n temerature:

   
adversely affect t e strent , ardness
 and wear 
 resistanceof t e cuttin tool
  
cause dimensional c an es in t e art ein mac ined, makin control of dimensio
 
nal accuracy difficult and can induce t ermal damae to t e mac ined surface, ad
versely affectin its roerties and service life.
Deartment of Industrial & Production Enineerin
18/13
      
In addition, t e mac ine toolitselfmay e su jected to  tem erature radients,
causin distortion of t e mac ine. 
     T e main sources of
 eat in metal cuttin are
s own in t e followin Fi ure. T ese t ree distinct eat sources are:

q1 q3 q2

C i

      
t e s ear zone (q1), w ere
 t e main lastic deformation takes lace t e c i
 too
l interface zone (q2), w ere secondary  lastic deformation due to friction etwe
    
en t e eated c i and 
t e tool takes lace t e work tool interface (q3), at fla
nks w ere frictional ru in occurs.
Workiece
Tool
      
T e eat alance in c i formation can

 in t e
e written as : Amount of eat away in c
i s +Amount of eat remainin
 Total amount
 = cuttin tool + Amou


nt of eat assin  
into t e work iece + Amount 
of eat enerated of eat r

adiated into t e surroundin air
Deartment of Industrial & Production Enineerin 18/14
    
Various studies ave een made of temeratures in cuttin, ased on eat transfe
r and dimensional analysis, usin exerimental data. A simle and aroximate ex
ression for te mean temerature for ortoonal cuttin is

0.4 U Vc t T= ρC K
whe e,
0..333
T = mean tempe atu e ise at the tool-chip inte face (oC) U = specific ene gy in
the ope ation (N-m/mm3) Vc = cutting velocity (m/sec) t = depth of cut (mm) pC
= volumet ic specific heat of the wo kpiece (J/mm2-C) K = the mal diffusivity (
atio of the mal conductivity to volumet ic specific heat) of the wo kpiece mate
ial (m2/sec).
Depa tment of Indust ial & P oduction Enginee ing
18/15
Exe cise
The dynamomete eco ded the following, feed fo ce 200 kg, cutting fo ce 300 kg.
The ake angle of the tool used was 10o. The chip thickness atio 0.35. Find

Shea angle (β)

 Shea fo ce (Ps) Co-efficient of f iction at the
 chip-tool inte
face (μ) and t e friction anle (η) Compressive force at t e s ear plane (Pn).
     
A seamless tu e 3cm outside diameteris reduced in lent on a lat e wit t e e

lp of a sin le point cuttin  tool. T e cuttin  speed is 40 m/min, t e dept of c
  
ut is 0.125mm. T e lent of continuous c ips, for one revolution of t e tu e, o
n measurementcomes to e 17.77cm. T e cuttin  force is 200 k and te feed forc

e is 75 k. t e rake anle of t e tool is 35o.Calculate,

   
Co-efficient
 of friction C ip t ickness
 ratio Sear
 plane
 anle Velocity of t e

c ip alon t e tool face Velocity of s ear alon t e s ear plane
18/16
Department of Industrial & Production Enineerin
Durin     
 t e mac inin
 of AISI-1025 steel, wit 0-10-6-6-8-90-1 (mm) ORS s aped to
ol t e followin o servations
 were taken:  
Feed 0.50 mm/rev Dept of cut = 2.0 mm Cuttin speed = 40 m/min T e s ear
anle = 20o T e power consumed w ilemacinin= 3kW T e power  consumed w ile
runnin idle = 0.50
  kW Calculate:
  T e s ear force C ip t ickness ratio No
rmal pressure on t e c ip C ip t ickness

Department of Industrial & Production Enineerin

18/17
Any questions or comments?
Department of Industrial & Production Enineerin
18/18