Chapter 2

MECHANICS OF
METAL CUTTING
Prof. Dr. S. Engin KILI
MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II

Content

Terms and Definitions

Chip Formation
Cutting Forces and Force
Diagram
Shear Angle
Orthogonal Cutting
Geometry
Mathematical Models
Metal Removal Rate
Power Requirement
Examples

Photos from internet

sites.

MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II

Terms and Definitions

Machining : Removal
of material in the form
of chips from the
workpiece by shearing
with a sharp tool.

Resultant Cutting Motion

in Cylindrical Turning

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Terms and Definitions

Kalpakjian-Schmid,
2008

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Terms and Definitions

Orthogonal Cutting

Oblique Cutting

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Terms and Definitions

Oblique Cutting

(a)

MFGE 307

Schematic illustration of cutting with an

oblique tool. (b)
Top view, showing the
inclination angle, i.
(c)
Types of chips produced with different
inclination
angles.
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Terms and Definitions

Orthogonal Cutting Analogy in Turning (for

0
=0
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Terms and Definitions

Relative Motion
between tool and
workpiece
Primary
motion

Secondary
motion

Cutting
motion

Feed
motion

Cutting
speed

Feed rate

Depth of cut
adjustment

Depth of cut

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Chip Formation

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Chip Formation

Shiny (burnished) surface on the

tool side of a continuous chip
produced in turning.
Basic types of chips produced in metal cutting
and their micrographs: (a) continuous chip with
narrow, straight primary shear zone; (b)
secondary shear zone at the tool-chip
interface; (c) continuous chip with built-up
edge;
(d)
serrated
(segmented
or
nonhomogeneous) chip; and (e) discontinuous
chip. Source: After M.C. Shaw, P.K. Wright, and
S. Kalpakjian.

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ME 303 - Section 05a

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Continuous Chip

Common in machining ductile materials

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Discontinuous Chip

Machining brittle
materials
Small rake angle
Large depth of cut
Machining ductile
materials at

low cutting speed

high feed

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Serrated Chip

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Continuous Chip with BUE

Occurs in machining
ductile materials with
high friction at toolchip interface
Chip welds to tool face
Destroys accuracy and
surface finish
Increases tool wear
Can be reduced by

decreasing depth of cut

increasing cutting
speed

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Cutting Forces

a0

ac

Fc: tangential (main) cutting

force

c u ttin g
to o l

Ft: thrust (feed) cutting force

Ff: frictional force on rake

Fs

Fc

Fn

Ft

Fr

Ff

c u ttin g
to o l

Fn: normal force on rake

Fs: shear force on shear plane
Fn : normal force on shear
s

plane
Fr: resultant force
shear angle

nnormal rake angle

MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II
Fn

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Cutting Forces
F 2 r Fc2 Ft 2 Fs2 Fn2s Fn2 F f2
tan( - n ) =

Ft
Fc

Fs Fc cos - Ft sin
Fns Fc sin Ft cos
F f Fc sin n + Ft cos n
Fn Fc cos n - Ft sin n
Ff
=
= tan
Fn
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Orthogonal Cutting Geometry

ac
a0
ls

sin cos n
ac
sin cos n
a0
ac
rc
a0
rc cos n
tan
1 rc sin n
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Theoretical Models

Only two of the simple thin shearzone models will be covered:

Ernst and Merchants model

Lee and Shaffers model

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Ernst and Merchant

Model
Common assumptions:

Sharp tool tip no

rubbing
or ploughing between tool
and
w.p.
Two dimensional
deformation
no side spread
Uniform stress distribution
on shear plane
Resultant force on shear
plane
equal and opposite to res.
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force at TECHNOLOGY
chip-tool interface.
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Main Assumption (EM Model)

Shear angle would take up such a value as to reduce

the work done in cutting to a minimum.

For given cutting conditions, work done in cutting is proportio

to Fc, it is necessary to develop an expression for Fc in terms o
and then to obtain the value of for which Fc is a minimum:

Fs Fr cos n

s Ac
Fs s As
sin
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Shear Angle (EM Model)

s shear strength of the work material on the shear plane
As area of the shear plane
A c cross - sectional area of the uncut chip
mean angle of friction
n normal rake angle

s Ac
1
Fc
0 to minimize Fc
sin cos n

Fc Fr cos n

2 n
s Ac cos n
2
Fc
sin cos n
Fr

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Work material is rigid plastic.

Elastic strain is negligible.
Behaviour of work material is
independent of the rate of
deformation.
Temperature effects are
neglected.
Inertia effects are neglected.
Uniform stress distribution at
the chip-tool interface.

Stress

Lee and Shaffers Model

Strain

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Main Assumptions (LS

Model)

A slip-line field is formed in the triangular

plastic zone extending from the shear plane
to the interface between the tool and the
chip where no deformation takes place
except for the transmission of forces from
tool-chip interface to shear plane and for the
material being stressed to its yield point.
All the deformation takes place in the plane
(Shear Plane) extending from the tool
cutting edge to the point of intersection of
the free surfaces of the work and the chip.

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Assumptions (Contd)

Maximum shear stress throughout the zone is s,

shear stress on the shear plane and two directions of
this max. shear stress are indicated by two orthogonal
sets of lines (slip lines).
Top surface of the triangular plastic zone then
becomes a free surface across which no stresses are
transmitted. Therefore between this surface and the
max. shear stress plane (shear plane) there is an
angle of /4.
Principal stresses act on the chip-tool interface
(secondary def. Zone) at angles and +/2.
Directions of max. shear stress lie at /4 to the dir. of
principal stress
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ME 303 - Section 05a

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Lee-Shaffer Theory
(Contd)

max
2

2 = 90o
Fr

45o

1
=

45o

45o

90o n

Hence,
n

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Metal Removal Rate

a

w = v.f.d

d
where,
w: metal removal rate
v: cutting speed
f
f
f: feed rate
cutting conditions
d: depth of cut
Ac: f.d = undeformed chip cross sectional
area
ac = f cos
Side Cutting Edge Angle
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Power Requirement
E: Energy required to remove unit volume of
chips
or
Resistance to cutting force

GJ
E 3 or GPa
m

GJ GN m GN
m 3 m 3 m 2 GPa

E Specific cutting energy Energy to remove unit volume of

chips
or
E Specific cutting pressure Force to produce chips with unit
MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II
cross
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sectional area

Power Requirement

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Power Requirement
Power required at the spindle:

E is a function of material property and the undeformed chip thickness

If Eo is the specific cutting energy for an undeformed chip thickness of 1
mm, then the specific cutting energy for a chip thickness ac :

E = Eo . (ac )

=>

so

ac

E = Power / Material Removal Rate

E = (Fc.v) / (v.f.d)

where ac = f . cos

E = (Fc . cos ) / (ac . d)

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Power Requirement

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Power Requirement

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ME 303 - Section 05a

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Power Requirement
EXAMPLE:
For an orthogonal cutting operation where v= 36 m/min f= 0.25 mm/rev it was found E
= 3.8 (W-sec/mm3) (m/min). If the power available at the spindle = 5 hp, find the
maximum metal removal rate and corresponding depth of cut. Note that 1 hp = 746 W.

Power 5 x746
w

E
3.8

mm 3
W
982

W
s
3
mm

N m
5 x746
Power
s 6216 N
F

36 m
v
60 s
mm 3
982
s
w

6.55mm
vf 36 x103 mm
x0.25mm
60 s

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Specific Cutting Energy

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Problem 1
In an orthogonal cutting test on mild steel, the following results
were obtained:
ac= 0.25 mm
a0= 0.75 mm
d = 2.5 mm

Fc = 900N
Ft = 450N
n = 100

a) Calculate the mean angle of friction on the tool rake

b) Calculate the cutting ratio
c) Calculate the shear angle
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Problem 2
For an orthogonal turning operation it was found that
power consumption of lathe when idle
= 325 W
power consumption of lathe when cutting = 2580 W
For the following conditions:
spindle speed, N = 124 rpm;
cutting speed, v = 24.5 m/min
depth of cut, d = 3.8 mm;
feed rate, f = 0.2 mm/rev
Find:
a) specific cutting energy of the work material,
b) torque at the spindle,
c) cutting force,
d) specific cutting energy for 1 mm undeformed chip thickness
assuming = 0.4.
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Problem 3
25 mm holes will be drilled on a steel workpiece, having a
hardness of Rc=45 {specific cutting energy, E = 77 W/(cm3/min)}
using an HSS twist drill at the following conditions:
cutting speed, v = 24.5 m/min
feed rate, f = 0.2mm/rev
Find:
a) the motor power if the efficiency of the transmission is 85%,
b) torque required.

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