Lecture Notes on Manufacturing Seience-II by Animesh Pal, Depariment of Mechanical E UNIT NO-I‘Lecture Notes on Manufacturing Sclenc-I by Animesh Pal, Department of Mechanica! Engineering, KIOT: Kenpur METAL CUTTING MECHANICS OF METAL CUTTING MACHINING Machining is an essential process of finishing by which jobs are produced to the desired dimensions and surface finish by gradually removing the excess material from the preformed blank in the form of chips with the help of cutting tools moved past the work surface. Machining. is a removal process, MACHINE TOOL, A machine tool is a non-portable power operated and reasonably valued device or system of device in which energy is expended to produce jobs of desired size, shape and surface finish by removing excess ‘material from the preformed blanks in the form of chips with the help of cutting tools moved past the work surface, Meterial removal is essentially done on machine tools, which may be Lathe, Milling, Drilling, Shaping, Planing, Broaching and Grinding machines. ‘The functions of machine tools are: + Holding the workpiece + Holding the tool * Moving the tool or the work piece or both relative to each other, * Supply energy required to cause metal cutting, Every machine tool has a primary cutting tool for metal removal METAL CUTTING: Machining is the process of removing unwanted material from W/P in the form of unwanted chip. If ‘the material is Metal then itis known as metal Cutting, ‘TYPES OF METAL CUTTING: GS two basic methods of metal cutting using a single point tool are the orthogonal (2 D) and obtique @D). 7 Orthogonal Cutting (2-D): Orthogonal cutting takes place when the cutting face of the tool is 90 degree to the line of action of the tool. 2. Oblique Cutting (3-D): Ifthe cutting face is inclined at an angle less than 90 degree to the line of action of the tool, the cutting action is known as oblique.‘Lecture Notes on Manufacturing Science-II by Animesh Pal, Department of Mechanical Engineering, KIOT, Kanpur DIFFERENCE BETWEEN ORTHOGONAL AND OBLIQUE CUTTING Orthogonal Cutting (2-D)_ Oblique Cutting (3-D)_ Mor chip Cutting edge Inclination cutting Gitect ion ‘The cutting edge of the tool remains normal {to the direction of tool feed or work feed. The direction of the chip flow velocity is normal to the cutting edge of the tool. The cutting edge of the tool remains inclined at an acute angle to the direction of tool feed or work feed The direction of the chip flow velocity is at an angle with the normal to the cutting edge of the tool. The angle is known as chip flow angle Here only two components of forces are acting: Cutting Force and Thrust Force. So the metal cutting may be considered as a two dimensional cutting. Here three components of forces are acting: Cuting Force, Radial force and Thrust Force or feed force. So the metal cutting may be considered as a three dimensional cutting Inclination angle is 0° Inclination angle is non Zero Chip get coiled in a tight way resulting heat Less concentration of heat and pressure and pressure | _| Less tool life More tool life Examples: Slotting, Parting, Planning. Examples: Milling, Turning, Drillin GEOMETRY OF SINGLE POINT TURNING TOOL Both material and geometry of the cutting tool play very important roles on their performances in achieving effectiveness, efficiency and overall economy of machining, CLASSIFICATION: (ACCORDING TO THE (POINTS) INVOLVED.) NUMBER OF MAJOR CUTTING EDGES + Single point: turning, shaping, planning, slotting tools etc. + Double point: drilling tools + Multipoint: Milling, broaching, hobbing tools etc.