Material Removal Process (Metal Machining Process) : Theory of Metal Cutting

Material Removal Process (Metal
Machining Process)
1.1
Theory of Metal Cutting

overview, theory of chip formation, force &
merchant equation, power & energy, cutting
temperature
1.2 Machining Operations and Machine Tools

turning, drilling, milling, machine centers,
cutting tool technology
BDA 3052 Manufacturing

Technology
Material Removal Processes

Introduction
It is shaping operations, it remove material

from a starting workpart so the remaining
part has the desired geometry
Divided into three main groups:
1) Machining material removal by a sharp
cutting tool, e.g., turning, milling, drilling
2) Abrasive processes material removal
by hard, abrasive particles, e.g., grinding
3) Nontraditional processes - various
energy forms other than sharp cutting tool
to remove material

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Why Machining is Important
Variety of work materials can be machined

Most frequently used to cut metals
Variety of part shapes and special
geometric features possible, such as:
Screw threads
Accurate round holes
Very straight edges and surfaces
Good dimensional accuracy and surface
finish

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Disadvantages with Machining
Wasteful of material
Chips generated in machining are wasted
material, at least in the unit operation
Time consuming
A machining operation generally takes
more time to shape a given part than
alternative shaping processes, such as
casting, powder metallurgy, or forming

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Machining in Manufacturing Sequence
Generally performed after other

manufacturing processes, such as casting,
forging, and bar drawing
Other processes create the general
shape of the starting workpart
Machining provides the final shape,
dimensions, finish, and special geometric
details that other processes cannot
create

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Machining
Nomenclature of single point tool

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Seven elements of singlepoint tool geometry; and

(b) the tool signature convention that defines the
seven elements.

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Orthogonal Cutting Model

Simplified 2-D model of machining that
describes the mechanics of machining
fairly accurately
Figure 21.6 Orthogonal cutting: (a) as a threedimensional process.

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Orthogonal and Oblique cutting

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Assumptions in orthogonal cutting

(Merchant theory)
01.The tool is perfectly sharp and no contact along clearance face.

02. The shear surface is a plane extending upward from the
cutting edge.
03.The cutting edge is a straight line, extending perpendicular to
the direction of motion and generates a plane surface as the work
moves past it.
04.The chip does not flow to either side.
05.The depth of cut is constant.
06.Width of the tool is greater than the work piece.
07.The work moves relative to the tool with uniform velocity.
08.A continuous chip is produced with no built up edge.
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Assumptions in orthogonal cutting

(Merchant theory)
09. Chip is assume to shear continuously

across plane AB on which the shear stress
reaches the value of shear flow stress.
10.Width of chip is remains equal to the width
of the work piece. i.e. Plane strain conditions
exist.

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Difference between orthogonal and

oblique cutting
Orthogonal cutting
Oblique cutting
01.The cutting edge of the tool is perpendicular to the

direction of the tool travel.
The cutting edge is inclined at angle with the normal

direction of the tool travel.
02. The cutting edge clears the width of the work piece
on either ends.
The cutting edge may or may not clear the width of the
workpiece.
03. The chip flows over the tool. The chip coils in tight.
The chip flows on the tool face making an angle with

the normal cutting edge. The chip flows side ways in a
long curl.
04. Only two components of the cutting force acting on

the tool.
Three components of the forces acting on the tool.
05.Maximum chip thickness occurs at the middle.
Maximum chip thickness may not occur at middle.
06. For the given feed rate and DOC, the force which
act or shears the metal acts on a smaller area and
therefore, the heat developed per unit area due to
friction along the tool work interface is less and the tool
life is less.
It acts on larger area and thus tool life is more.
Machining
Cutting action involves shear deformation of

work material to form a chip
As chip is removed, new surface is exposed
(a) A crosssectional view of the machining process, (b) tool with

negative rake angle; compare with positive rake angle in (a).

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Cutting Process in Turning

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Cutting Process in Turning

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Relationship between chip thickness,

rake angle and shear plane angle
r
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l s sin
sin
l s cos( )
cos( )
Chip Thickness Ratio

to
r
tc
where r = chip thickness ratio; to = thickness of
the chip prior to chip formation; and tc = chip
thickness after separation
Chip thickness after cut always greater

than before, so chip ratio always less than
1.0

Technology
Determining Shear Plane Angle
Based on the geometric parameters of the

orthogonal model, the shear plane angle
can be determined as:
r cos
tan
1 r sin
where r = chip ratio, and = rake angle

Technology
Example of Problem
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 tc = 1.125 mm. Calculate
the shear
plane angle and the shear strain in the operation.
Answer : = 25.4
= 2.386

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Example of Problem 2
In an orthogonal cutting operation, the tool has a
rake
angle = 15. The chip thickness before the cut =
0.30
mm and the cut yields a deformed chip thickness
= 0.65
mm. Calculate (a) the shear plane angle and (b)
the
shear strain for the operation.

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Shear Strain in Chip Formation
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.
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Shear Strain
Shear strain in machining can be computed
from the following equation, based on the
preceding parallel plate model:
AC
AD DC
BD
BD
= tan( - ) + cot
where = shear strain, = shear plane angle, and =
rake angle of cutting tool
Technology
In an orthogonal cutting operation, the tool has a
rake
angle = 15. The chip thickness before the cut =
0.30
mm and the cut yields a deformed chip thickness
= 0.65
mm. Calculate (a) the shear plane angle and (b)
the
shear strain for the operation.

Technology
Chip Formation
More realistic view of chip formation, showing shear zone

rather than shear plane. Also shown is the secondary shear
zone resulting from toolchip friction.
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Four Basic Types of Chip in Machining

1.
2.
3.
4.
Discontinuous chip
Continuous chip
Continuous chip with Built-up Edge (BUE)
Serrated chip

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1. Discontinuous Chip
Brittle work
materials
Low cutting
speeds
Large feed and
depth of cut
High toolchip
friction

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2. Continuous Chip
Ductile work
materials
High cutting
speeds
Small feeds and

depths
Sharp cutting
edge
Low toolchip
friction

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Continuous with BUE
Ductile materials
Lowtomedium
cutting speeds
Tool-chip friction
causes portions of
chip to adhere to
rake face
BUE forms, then
breaks off,
cyclically

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Serrated Chip
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

Technology
Figure 21.9 (d) serrated.
Effect of Higher Shear Plane Angle
Higher shear plane angle means smaller

shear plane which means lower shear force,
cutting forces, power, and temperature
Effect of shear plane angle : (a) higher with a resulting lower shear
plane area; (b) smaller with a corresponding larger shear plane
area. Note that the rake angle is larger in (a), which tends to increase
shear angle according to the Merchant equation
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Forces Acting on Chip
Friction force F and Normal force to friction N

Shear force Fs and Normal force to shear Fn
Forces in metal cutting: (a)

forces acting on the chip in
orthogonal cutting

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Resultant Forces
Vector addition of F and N = resultant R

Vector addition of Fs and Fn = resultant R'
Forces acting on the chip must be in
balance:
R must be equal in magnitude to R
R must be opposite in direction to R
R must be collinear with R

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Cutting Forces

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Cutting Forces

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Cutting Forces

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Coefficient of Friction
Coefficient of friction between tool and chip:
F

N
-(1)
Friction angle related to coefficient of friction

as follows:
tan
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-(2)
Shear Stress
Shear stress acting along the shear plane:
Fs
S
-(3)
As
where As = area of the shear plane
As
t ow
sin
-(4)
Shear stress = shear strength of work material

during cutting

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Cutting Force and Thrust Force
F, N, Fs, and Fn cannot be directly measured
Forces acting on the tool that can be measured:

Cutting force Fc and Thrust force Ft
Forces in metal
cutting: (b) forces
acting on the tool that
can be measured

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Merchants circle diagram

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Merchants circle diagram

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Forces in Metal Cutting
Equations can be derived to relate the forces

that cannot be measured to the forces that
can be measured:
F = Fc sin + Ft cos (5)
N = Fc cos Ft sin (6)
Fs = Fc cos Ft sin (7)
Fn = Fc sin + Ft cos (8)
Based on th ese calculated force, shear

stress and coefficient of friction can be
determined

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Cutting force = 1559 N
Thrust force = 1271 N
Width of cutting = 3 mm
Rake angle = 10
Shear plane angle = 25.4
Original Thickness = 0.5 mm
Determine the shear strength of the work
material.
shear stress, S / shear strength, = 247 N/mm2
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Forces in Metal Cutting
From equation 3, the force diagram (Merchant s Circle

Diagram), can be used to derived the following equations:
St o w cos( )
Fs cos( )
Fc
sin cos( ) cos( )
St o w sin( )
Fs sin( )
Ft
sin cos( ) cos( )

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The Merchant Equation
From equation 3, 4 and 7, Merchant Equation for shear stress can

be expressed as,
Fc cos Ft sin

(to / sin )

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The Merchant Equation
Of all the possible angles at which shear

deformation can occur, the work material
will select a shear plane angle that
minimizes energy, given by

45
2 2
Derived by Eugene Merchant

Based on orthogonal cutting, but validity
extends to 3-D machining

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What the Merchant Equation Tells Us

45
2 2
To increase shear plane angle

Increase the rake angle
Reduce the friction angle (or coefficient
of friction)

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Power and Energy Relationships
A machining operation requires power

The power to perform machining can be
computed from:
Pc = Fc
where Pc = cutting power (Nm/s); Fc = cutting

force
(N); and = cutting speed (m/min)
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In U.S. customary units, power is traditional expressed as

horsepower
HPc = Fc/33,000
where HPc = cutting horsepower, hp

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Gross power to operate the machine tool Pg

or HPg is given by
Pc
Pg
E
or
HPc
HPg
E
where E = mechanical efficiency of machine tool

Typical E for machine tools 90%

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Unit Power in Machining
Useful to convert power into power per unit

volume rate of metal cut
Called unit power, Pu or unit horsepower, HPu
Pc
PU
MRR
or
HPc
HPu
MRR
where MRR = material removal rate (mm3/s)

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Specific Energy in Machining

Unit power is also known as the specific energy U
Pc
Fc v
Fc
U Pu
MRR vto w to w
Units for specific energy are typically Nm/mm 3
or J/mm3

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Cutting Temperature
Approximately 98% of the energy in

machining is converted into heat
This can cause temperatures to be very
high at the toolchip
The remaining energy (about 2%) is
retained as elastic energy in the chip

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Cutting Temperature is
Important
High cutting temperatures
1. Reduce tool life
2. Produce hot chips that pose safety hazards
to the machine operator
3. Can cause inaccuracies in part dimensions
due to thermal expansion of work material

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Cutting Temperature
Analytical method derived by Nathan Cook

from dimensional analysis using
experimental data for various work materials
0.4U vt o
T
C K
0.333
where T = temperature rise at toolchip

interface; U = specific energy; v = cutting
speed; to = chip thickness before cut; C =
volumetric specific heat of work material; K =
thermal diffusivity of work material
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Example Problem 6
Cutting speed = 100 m/min
Chip original thickness = 0.5 mm
Thermal diffusivity = 50 mm2/s
Specific Energy = 1.038
Volumetric specific heat work material = 3 x10-3
J/mm3
Find the mean temperature rise at the tool-chip
Interface.

Technology
Cutting Temperature
Experimental methods can be used to measure

temperatures in machining
Most frequently used technique is the
toolchip thermocouple
Using this method, Ken Trigger determined the
speedtemperature relationship to be of the
form:
T = K vm
where T = measured toolchip interface
temperature, and v = cutting speed
K and m depend on the cutting conditions and
work material

Technology
Machining
A material removal process in which a sharp
cutting tool is used to mechanically cut away
material so that the desired part geometry
remains
Most common application: to shape metal parts
Most versatile of all manufacturing processes in
its capability to produce a diversity of part
geometries and geometric features with high
precision and accuracy
Casting can also produce a variety of shapes,
but it lacks the precision and accuracy of
machining
Classification of Machined Parts
Rotational - cylindrical or disklike shape

Nonrotational (also called prismatic) blocklike or platelike
Machined parts are classified as: (a) rotational, or (b) nonrotational,

shown here by block and flat parts.
Machining Operations and Part

Geometry
Each machining operation produces a
characteristic part geometry due to
two factors:
1. Relative motions between tool and
workpart
Generating part geometry

determined by feed trajectory of
cutting tool
2. Shape of the cutting tool
Forming part geometry is created

by the shape of the cutting tool
Generating Shape
Figure 22.2 Generating shape: (a) straight turning, (b) taper

turning, (c) contour turning, (d) plain milling, (e) profile milling.
Forming to Create Shape
Forming to create shape: (a) form turning, (b) drilling, and (c)
broaching.
Forming and Generating
Combination of forming and generating to create shape: (a)

thread cutting on a lathe, and (b) slot milling.
Turning
Single point cutting tool removes material
from a rotating workpiece to generate a
cylinder
Performed on a machine tool called a lathe
Variations of turning performed on a lathe:
Facing
Contour turning
Chamfering
Cutoff
Threading
Turning
Turning operation.
Turning Operation
Close-up view of a
turning operation on
steel using a titanium
nitride coated carbide
cutting insert (photo
courtesy of Kennametal
Inc.)
Facing
Tool is fed
radially inward
Contour Turning
Instead of feeding
tool parallel to axis of
rotation, tool follows a
contour that is other
than straight, thus
creating a contoured
shape
Chamfering
Cutting edge cuts an angle on the corner

of the cylinder, forming a "chamfer"
Cutoff
Tool is fed radially into rotating work at

some location to cut off end of part
Cutoff
Tool is fed radially into rotating work at

some location to cut off end of part
Threading
Pointed form tool is fed linearly across surface

of rotating workpart parallel to axis of rotation
at a large feed rate, thus creating threads
Cutting Conditions in Turning - 1
The rotational speed in turning related to the desired

cutting
speed at the surface of the cylindrical workpiece by
the
equation:
N
D
N = rotational speed, rev/min; = cutting speed,

m/min,
And Do = original diameter of the part, m.
The change in diameter is determined by the depth

of cut,
d:
Do Df = 2d
Do = original diameter, mm; Df = final diameter,
mm
d = depth of cut
The feed in turning is generally expressed in

mm/rev. This
feed can be converted to linear travel rate in
mm/min by the
formula:
fr = Nf
fr = feed rate, mm/min; f = feed mm/rev
The time to machine from one end of a cylindrical

workpart
to the other is given by:
Tm = L/fr
Tm = time of actual machining, minutes; and L =
length of
the cylindrical workpart, mm
The volumetric rate of material removal rate can be

most
conveniently determined by the following equation:
MRR = vfd
MRR = material removal rate, mm3/min, f = feed,
mm
Cutting Conditions in Turning

Problem 1
A cylindrical workpart 200 mm in diameter
and 700 mm long is to be turned in an
engine lathe. Cutting conditions are as
follows: cutting speed is 2.30 m/s, feed is
0.32 mm/rev, and depth of cut is 1.80
mm.
Determine (a) cutting time, and (b)
metal removal rate.

Problem 1
A cylindrical workpart 200 mm in diameter
and 700 mm long is to be turned in an
engine lathe. Cutting conditions are as
follows: cutting speed is 2.30 m/s, feed is
0.32 mm/rev, and depth of cut is 1.80
mm.
Determine (a) cutting time, and (b)
metal removal rate.

Problem 2
A work materials are to be turned to final size of
175 mm length having diameter of 60 mm.
Total length of the work material is 300 mm. A
single point tool having a certain degree of rake
angle is used. The work material rotates at 1400
RPM. The feed is 0.35 mm / revolution.
Final size of the work material is 51 mm.
Calculate:
1. Cutting velocity,
2. Time taken to machine to the length of 55 mm,
3. Total Material removal rate to get 51 mm diameter.
Milling
Machining operation in which work is fed past
a rotating tool with multiple cutting edges
Axis of tool rotation is perpendicular to
feed
Creates a planar surface
Other geometries possible either by
cutter path or shape
Other factors and terms:
Interrupted cutting operation
Cutting tool called a milling cutter,
cutting edges called "teeth"
Machine tool called a milling machine
Peripheral Milling vs. Face Milling
Peripheral milling
Cutter axis parallel to surface being
machined
Cutting edges on outside periphery of
cutter
Face milling
Cutter axis perpendicular to surface
being milled
Cutting edges on both the end and
outside periphery of the cutter
METHODS OF MILLING-1
1) Up milling is also referred to as conventional
milling. The direction of the cutter rotation
opposes the feed motion. For example, if the
cutter rotates clockwise , the workpiece is fed
to the right in up milling.
METHODS OF MILLING-2
2) Down milling is also referred to as climb
milling. The direction of cutter rotation is
same as the feed motion. For example, if the
cutter rotates counterclockwise , the
workpiece is fed to the right in down milling
Slab Milling
Basic form of peripheral milling in

which the cutter width extends beyond
the workpiece on both sides
Slotting
Width of cutter is less than workpiece width,

creating a slot in the work
Conventional Face Milling

Cutter overhangs
work on both sides
Profile Milling
Form of end milling
in which the
outside periphery
of a flat part is cut
Pocket Milling
Another form
of end milling
used to mill
shallow
pockets into
flat parts
Surface Contouring
Ballnose cutter
fed back and forth
across work along
a curvilinear path
at close intervals
to create a three
dimensional
surface form
End Milling
Cutter diameter
is less than work
width, so a slot
is cut into part
Machining Centers
Highly automated machine tool can
perform multiple machining operations
under CNC control in one setup with
minimal human attention
Typical operations are milling and
drilling
Three, four, or five axes
Other features:
Automatic toolchanging
Pallet shuttles
Automatic workpart positioning
Milling Operation
High speed face

milling using
indexable inserts
(photo courtesy
of Kennametal
Inc.).
Cutting Conditions in Milling - 1

The cutting speed is determined at the
outside diameter of a milling cutter.
N
D
N = rotational speed, rev/min; = cutting
speed, m/min,
And Do = outside diameter of a milling
cutter,mm.
The feed, f in milling is usually given as a feed per cutter

tooth; called the chip load, it represents the size of the
chip
formed by each cutting edge.
fr = Nnt f
fr = feed rate, mm/min; N = spindle speed, rev/min; n t =
number of teeth on the cutter; f = chip load in mm/tooth
The feed, f in milling is usually given as a feed per cutter

tooth; called the chip load, it represents the size of the
chip
formed by each cutting edge.
fr = Nnt f
fr = feed rate, mm/min; N = spindle speed, rev/min; n t =
number of teeth on the cutter; f = chip load in mm/tooth
The material removal rate,
MRR = wdfr
w = width; d = depth of cut; fr = feed rate, mm/min;
Peripheral Milling
Approach distance A, to reach full cutter depth given

by:
d (D d )
d = depth of cut, mm, and D = diameter of the

milling cutter,
mm
The time to mill the workiece Tm is

therefore;
L A
Tm
fr
Face Milling cutter is centered
Where A and O are each to half the

cutter
diameter;
A = O = D/2
D= cutter diameter, mm
Face Milling cutter is offset
Where A and O are each to half the

cutter
diameter;
A O w( D w)
w= width of the cut, mm
The time to mill the workiece in face

milling,Tm is therefore;
L 2A
Tm
fr
Cutting Conditions in Milling

Problem 1
A peripheral milling operation is performed
on the top surface of a rectangular
workpart which is 400 mm long by 60 mm
wide. The milling cutter, which is 80 mm in
diameter and has five teeth, overhangs the
width of the part on both sides. The cutting
speed is 70 m/min, the chip load is 0.25
mm/tooth, and the depth of cut is 5.0 mm.
Determine (a) the time to make one pass
across the surface, and (b) the maximum
material removal rate during the cut.
Cutting Conditions in Milling

Problem 2
A face milling operation is performed to finish
the top surface of a steel rectangular work
piece 350 mm long by 55 mm wide. The milling
cutter has four teeth (cemented carbide inserts)
and a 85 mm diameter. Cutting conditions are:
v = 600 m/min, f = 0.35 mm / tooth, and d =
3.5 mm.
Determine:
a) the time to make one pass across the surface.
b) the metal removal rate during the cut.
Drilling
Creates a round
hole in a
workpart
Compare to
boring which can
only enlarge an
existing hole
Cutting tool
called a drill or
drill bit
Machine tool:
drill press
Through Holes vs. Blind Holes

Throughholes - drill exits opposite side of work
Blindholes does not exit work opposite side
Two hole types: (a) throughhole, and (b) blind hole.
Reaming
Used to slightly
enlarge a hole,
provide better
tolerance on
diameter, and
improve surface
finish
Tapping
Used to provide
internal screw
threads on an
existing hole
Tool called a tap
Counterboring
Provides a
stepped hole, in
which a larger
diameter follows
smaller diameter
partially into the
hole
Cutting Conditions in Drilling - 1

Letting N represent the spindle
rev/min,
N
D
= cutting speed, m/min; D = the

drill diameter,mm.
Feed can be converted to feed rate using the the

same
equation as for turning:
fr = Nf
fr = feed rate, mm/min; N = spindle speed, rev/min;
f = feed
in drilling, mm/rev

The time to drill through holes;
tA
Tm
fr
Tm= machining time, min; t = work thickness,
mm; fr = feed rate, mm/min

The allowance is given by;
A 0.5 D tan 90
2
A = approach allowance, mm; = drill point

angle

The time to drill blind holes;
d
Tm
fr
Tm= machining time, min; d = hole depth,
mm; fr = feed rate, mm/min
Cutting Conditions in Drilling

Problem 1
A drilling operation is to be performed with a
12.7 mm diameter twist drill in a steel
workpart. The hole is a blind hole at a depth of
60 mm and the point angle is 118. The cutting
speed is 25 m/min and the feed is 0.30
mm/rev.
Determine
(a) the cutting time to complete the drilling
operation, and
(b) metal removal rate during the operation,
after the drill bit reaches full diameter.
CUTTING TOOL TECHNOLOGY

1.
2.
3.
4.
Tool Life
Tool Materials
Tool Geometry
Cutting Fluids
Cutting Tool Technology

Two principal aspects:
1. Tool material
2. Tool geometry
Three Modes of Tool Failure

1.
2.
3.
Fracture failure
Cutting force becomes excessive and/or
dynamic, leading to brittle fracture
Temperature failure
Cutting temperature is too high for the
tool material
Gradual wear
Gradual wearing of the cutting tool
Preferred Mode: Gradual Wear
Fracture and temperature failures are

premature failures
Gradual wear is preferred because it leads
to the longest possible use of the tool
Gradual wear occurs at two locations on a
tool:
Crater wear occurs on top rake face
Flank wear occurs on flank (side of tool)
Tool Wear
Figure 23.1 Diagram of worn cutting tool, showing the principal

locations and types of wear that occur.
Figure 23.2 Crater wear,

(above), and flank wear (right) on
a cemented carbide tool, as seen
through a toolmaker's
microscope (photos by K. C.
Keefe, Manufacturing Technology
Lab, Lehigh University).
FLANK WEAR and BUE
CRATER WEAR
BUILT UP EDE
Taylor Tool Life Equation

Relationship is credited to F. W. Taylor
vT n C
where v = cutting speed; T = tool life; and n
and C are parameters that depend on feed,
depth of cut, work material, tooling material,
and the tool life criterion used
n is the slope of the plot
C is the intercept on the speed axis at one
minute tool life
Tool Life Criteria in Production

1.
2.
3.
4.
5.
6.
7.
8.
9.
Complete failure of cutting edge

Visual inspection of flank wear (or crater
wear) by the machine operator
Fingernail test across cutting edge
Changes in sound emitted from
operation
Chips become ribbon-like, stringy, and
difficult to dispose of
Degradation of surface finish
Increased power
Workpiece count
Cumulative cutting time
Tool Materials
Tool failure modes identify the important

properties that a tool material should
possess:
Toughness to avoid fracture failure
Hot hardness ability to retain hardness
at high temperatures
Wear resistance hardness is the most
important property to resist abrasive
wear

Material Removal Process (Metal Machining Process) : Theory of Metal Cutting

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Material Removal Process (Metal

Theory of Metal Cutting

1.2 Machining Operations and Machine Tools

BDA 3052 Manufacturing

Material Removal Processes

It is shaping operations, it remove material

BDA 3052 Manufacturing

Why Machining is Important

Variety of work materials can be machined

BDA 3052 Manufacturing

Disadvantages with Machining

BDA 3052 Manufacturing

Machining in Manufacturing Sequence

Generally performed after other

BDA 3052 Manufacturing

BDA 3052 Manufacturing

Seven elements of singlepoint tool geometry; and

BDA 3052 Manufacturing

Orthogonal Cutting Model

Figure 21.6 Orthogonal cutting: (a) as a threedimensional process.

Orthogonal and Oblique cutting

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Assumptions in orthogonal cutting

01.The tool is perfectly sharp and no contact along clearance face.

Assumptions in orthogonal cutting

09. Chip is assume to shear continuously

BDA 3052 Manufacturing

Difference between orthogonal and

01.The cutting edge of the tool is perpendicular to the

The cutting edge is inclined at angle with the normal

The chip flows on the tool face making an angle with

04. Only two components of the cutting force acting on

Three components of the forces acting on the tool.

05.Maximum chip thickness occurs at the middle.

Maximum chip thickness may not occur at middle.

It acts on larger area and thus tool life is more.

Cutting action involves shear deformation of

(a) A crosssectional view of the machining process, (b) tool with

BDA 3052 Manufacturing

Cutting Process in Turning

BDA 3052 Manufacturing

Cutting Process in Turning

BDA 3052 Manufacturing

Relationship between chip thickness,

Chip Thickness Ratio

Chip thickness after cut always greater

BDA 3052 Manufacturing

Determining Shear Plane Angle

Based on the geometric parameters of the

BDA 3052 Manufacturing

BDA 3052 Manufacturing

BDA 3052 Manufacturing

Shear Strain in Chip Formation

Shear strain during chip formation: (a) chip formation depicted as

BDA 3052 Manufacturing

More realistic view of chip formation, showing shear zone

Four Basic Types of Chip in Machining

BDA 3052 Manufacturing

BDA 3052 Manufacturing

Small feeds and

BDA 3052 Manufacturing

Continuous with BUE