Manufacturing Lecture

Manufacturing Technology I
ME 307
Chapter # 21
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
THEORY OF METAL MACHINING
Overview of Machining Technology
Theory of Chip Formation in Metal Machining
Force Relationships and the Merchant
Equation
Power and Energy Relationships in Machining
Cutting Temperature
References:
Fundamentals of Modern Manufacturing:
materials, processes, and systems, 3nd Ed., by
Mikell P. Groover, JOHN WILEY & SONS,
INC., 2007. (Chapter 21, pages 486-490)

Simulation of actual machining processes
After Ghosh, A. and Mallik, A.K. Manufacturing Science
Simplified 2-D model of machining that describes
the mechanics of machining fairly accurately
Figure 21.6 Orthogonal cutting: (a) as a three-dimensional processs, and
(b) how it reduces to two dimensions in FIGURE 21.6 the side view.

.
Orthogonal Cutting Model
Chip Thickness Ratio
where r = chip thickness ratio; t
o
=
thickness of the chip prior to chip
formation; and t
c
= chip thickness after
separation
Chip thickness after cut always greater than
before, so chip ratio always less than 1.0
r=
t
o
t
c
Determining Shear Plane Angle
Based on the geometric parameters of the
orthogonal model, the shear plane angle can
be determined as:
where r = chip ratio, and = rake angle
tan =
r cos
1 r sin
Figure 21.7 Shear strain during chip formation: (a) chip formation
depicted as a series of parallel plates sliding relative to each other, (b)
one of the plates isolated to show shear strain, and (c) shear strain
triangle used to derive strain equation.
Shear Strain in Chip Formation
Shear Strain
Shear strain in machining can be computed
from the following equation, based on the
preceding parallel plate model:

= tan( - ) + cot

where = shear strain, = shear plane
angle, and = rake angle of cutting tool
Example 21.1
In a machining operation that approximates
orthogonal cutting, the cutting tool has a
rake angle = 10 . The chip thickness
before the cut to = 0.50 mm and the chip
thickness after the cut t
c
= 1.125 in.
Calculate the shear plane angle and the
shear strain in the operation.

Figure 21.8 More realistic view of chip formation, showing shear
zone rather than shear plane. Also shown is the secondary shear
zone resulting from tool-chip friction.
Chip Formation
Chip Formation
After Materials and Processes in Manufacturing, by E. Paul DeGarmo,
J.T. Black, and Ronald A. Kohser, Prentice Hall of India, 2001
Four Basic Types of Chip in Machining
Discontinuous chip
Continuous chip
Continuous chip with Built-up Edge (BUE)
Serrated chip
Brittle work materials
Low cutting speeds
Large feed and depth
of cut
High tool-chip friction

Figure 21.9 Four types of
chip formation in metal
cutting: (a) discontinuous
Discontinuous Chip
Ductile work materials
High cutting speeds
Small feeds and
depths
Sharp cutting edge
Low tool-chip friction

Figure 21.9 (b) continuous
Continuous Chip
Ductile materials
Low-to-medium cutting
speeds
Tool-chip friction
causes portions of chip
to adhere to rake face
BUE forms, then
breaks off, cyclically
Figure 21.9 (c) continuous
with built-up edge
Continuous with BUE
Semicontinuous - saw-
tooth appearance
Cyclical chip forms with
alternating high shear
strain then low shear
strain
Associated with difficult-
to-machine metals at high
cutting speeds (e.g.
titanium alloys, nickel-
base superalloys, and
austenitic stainless
steels)
However, it is also found
with common metals at
high speeds.
Serrated Chip (shear-localized)
Figure 21.9 (d) serrated.
After Materials and Processes in Manufacturing, by E. Paul DeGarmo, J.T. Black,
and Ronald A. Kohser, Prentice Hall of India, 2001
Chips Produced in
Orthogonal Metal
Cutting
Figure 21.5 Basic types of chips produced in orthogonal metal cutting, their schematic
representation, and photomicrographs of the cutting zone: (a) continuous chip with narrow,
straight, and primary shear zone; (b) continuous chip with secondary shear zone at the cip-tool
interface; (c) built-up edge; (d) segmented or nonhomogeneous chip; and (e) discontinuous chip.
Source: After M.C. Shaw, P.K. Wright, and S. Kalpakjian.
Built-up Edge
Figure 21.6 (a) Hardness distribution with a built-up edge in the cutting zone (material, 3115
steel). Note that some regions in the built-up edge are as much as three times harder than the bulk
metal of the workpiece. (b) Surface finish produced in turning 5130 steel with a built-up edge.
(c) Surface finish on 1018 steel in face milling. Magnifications: 15x. Source: Courtesy of
Metcut Research Associates, Inc.
(b)
(c)
Chip Breaker
Figure 21.7 (a) Schematic
illustration of the action of a chip
breaker. Note that the chip breaker
decreases the radius of curvature of
the chip and eventually breaks it. (b)
Chip breaker clamped on the rake
face of a cutting tool. (c) Grooves in
cutting tools acting as chip breakers.
Most cutting tools used now are
inserts with built-in chip breaker
features.
Chips Produced in Turning
Figure 21.8 Chips produced in turning: (a) tightly curled chip; (b) chip hits workpiece and breaks;
(c) continuous chip moving radially away from workpiece; and (d) chip hits tool shank and breaks
off. Source: After G. Boothroyd.
Cutting with an Oblique Tool
Figure 21.9 (a) Schematic illustration of cutting with an oblique tool. Note the
direction of chip movement. (b) Top view, showing the inclination angle, i,. (c)
Types of chips produced with tools at increasing inclination angles.
Right-hand Cutting Tool and Insert
Figure 21.20 (a) Schematic illustration of right-hand cutting tool. The various angles on
these tools and their effects on machining are described in Section 23.3.1 Although these
tools traditionally have been produced from solid tool-steel bars, they have been replaced
largely with (b) inserts made of carbides and other materials of various shapes and sizes.

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Manufacturing Technology I

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