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Orthogonal Machining
Introduction:
Machining can be defined as the process of removing material from a workpiece in the form
of chips by a sharp cutting to leave the desired part shape. The predominant cutting action in
machining involves shear deformation of the work-piece to form a chip; as the chip is removed, a
new surface is exposed. A typical machining process is illustrated in Figure 3.1.
A cutting tool has one or more sharp cutting edges and is made of a material harder than that
of work material. It usually achieves their motion relative to workpiece by rotating. The cutting edge
serves to separate a chip from the workpiece. There are two surfaces connected to the cutting edge:
the rake face and the flank. The rake face, which directs the flow of chips, is oriented at a certain
angle called the rake angle, α. The rake angle can be positive or negative. The flank of the tool
provides a clearance between the tool and the newly generated work surface, thus protecting the
surface from abrasion. The rake face and flank are shown in Figure 3.2.
𝑡𝑡0
𝑟𝑟𝑐𝑐 =
𝑡𝑡𝑐𝑐
The governing equations in a machining process are provided below:
Shear angle: Shear strain:
Force Relationships
Several forces act during the cutting process. A normalized force diagram is shown in Figure 3.3.
Figure 3.3. Forces in orthogonal cutting: (a) Forces acting on the chip, and (b) forces on the tool.
MRR=(𝑡𝑡0 ∗ 𝑑𝑑)𝑉𝑉
Objective:
1. Understand the basic mechanics of chip formation.
2. Study the effect of rake angle, material system and the depth of cut on the process.
Equipment & Materials:
1. Vertical milling machine
2. Tool deflection gauge
3. Cutting tools with different rake angles (10°, 20°, 30°)
4. Workpiece: 6061 Aluminum, Brass
5. Dial calipers, protractor
Procedure:
1. Mount the aluminum work piece in the vise and the 10° cutting tool in the fixture. (The
rake angle is α in the calculation section).
2. Measure the distance from the bottom of the tool fixture to the point where the dial
indicator touches the tool. (This is the length L in the calculation section).
3. Adjust the X-axis feed rate (fr) to 4 inches per minute using the settings on the feed motor.
4. Turn on the CCD camera and monitor. With the cutting tool resting on the work piece,
adjust the camera so that the work piece fills approximately the bottom third of the screen
and the cutting tool appears on the right side of the screen. (*Note, focus the camera on
the work piece material, only a visible outline of the tool is needed).
5. Touch off on the top of the work piece then set the depth of cut to .003”. (This is to in the
calculation section).
6. Feed the tool into the work piece. Take an average reading from the tool deflection dial
indicator. Using a protractor, measure the shear angle on the screen. (These are δ and φ in
the calculations).
7. Collect the chip and measure the thickness with the dial calipers. (This is tc in the
calculations).
8. Repeat steps 1-7 at a depth of .006”.
9. Repeat steps 1-8 for the 20° rake angle tool.
10. Repeat steps 1-8 for the 30° rake angle tool.
11. Repeat steps 1-10 for brass.
References:
1. M.P. Groover, “Fundamentals of modern manufacturing,” 3rd edition, (2007).
2. F. Jones, H. Ryffel, E. Oberg, C. McCauley, and R. Heald, “Machinary’s handbook,” 26th
edition, Industrial Press, (2000).
3. You can see the chip formation for different conditions at
http://machine-tools.netfirms.com/Assets/FlashMovies/chip-formation-animation-2.htm
http://machine-tools.netfirms.com/Assets/FlashMovies/chip-formation-no-rake-angle.htm
Brass
10° Aluminum
20° Brass
30°