6-Mechanics of cutting

(Using multipoint cutting tool)

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Broach
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Broaches 4
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Side milling cutter / HSS 7
Plain milling. Milling of a flat surface with the axis of the cutter
parallel to the machining surface. It can be carried out either on a
horizontal machine or a vertical machine as shown in figure

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Multi-point cutter
O

C A
β T
B
Work

S
Feed velocity, f

Details of chip formation

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• Diameter of cutter, D >> depth of cut, d
• Number of teeth of the cutter = Z
• Spindle speed of cutter = N
• Feed of the table = f mm/min
• Angle of contact of a tooth with the work ≈ β

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Chip formation during slab milling
• AB ˜ AC sinβ
f
Effective .feed / tooth =
NZ
f sin β
t1 max ˜
NZ

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 OT D D
cos β ≈ = ( − d) /
OA 2 2
2d
sin β = [1 − (cos β)^ 2] = [1 − (1 − )^ 2]
D
d
......... ≈ 2
D
t1 max ≈ NZ2f d
D

t1ave ≈ NZf d
D
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Multi-teeth cutter

Arbor torque, M
FT Mmax

β=2πZ
β

β
Work
Arbor rotation
Variation of arbor torque due
Feed velocity, f to a single cutting tooth
FC

Arbor rotation and resisting torque

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Overall torque(M)

• 3 possibilities
β < 2π/Z
β = 2π/Z
β > 2π/Z

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 β<2πZ

Overall torque, M
Mmax

Mave

β
Arbor rotation

β=2πZ
Overall torque, M

Overall torque, M
Mmax
Mmax

Mave
Mave

β β β>2πZ
Arbor rotation Arbor rotation

Overall torque due to all cutting teeth 16

 Maximum cutting force (Fcmax)

wt1 max τs cos(λ − α)

Fc max =
sin φ cos(φ + λ − α)
Area.of .curve
Mave =
Angle.between.two.con sec utive.teeth

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 Machining time, t
(for slab milling, grinding etc)
Milling cutter / Grinding wheel

le Work piece

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 l + lc
t=
v
l = length of work piece
lc = extent of cutter’s first contact = D/2
D = diameter of the cutter
v = linear speed (feed rate of the work piece)
w = width of cut
d = depth of cut
Power = specific energy x MRR
MRR = vwd = lwd/t; lc << l

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