Production

Techniques-II
ME F313

Mechanics of turning process

Basic Scheme of Turning

Details of turning geometry

Cutting Velocity

Feed
Feed rate
Time of cut

Depth of cut

Chip thickness
Uncut chip thickness
Area of uncut chip

True feed

True depth of cut

During turning operation with a 8-14-6-6-8-15-

ASA cutting
tool at a feed of 0.2 mm/revolution, cutting speed 140
mm/min, depth of cut of 2 mm, a chip thickness of 0.4 mm
and a chip width of 2.2 mm has been observed. Calculate
Side cutting edge angle.
Principal cutting edge angle
True feed in mm/rev
Uncut chip thickness
True depth of cut
Chip reduction coefficient
Cutting ratio
Shear angle

Ans:
a) From the ASA system, it is known that side cutting edge angle is 15 o . So principal
cutting angle = (90-15) = 75o
b) Uncut layer thickness= (feed per rev.) * sin (principal cutting edge angle)
= 0.2 * sin (75)
= 0.193mm
c) True depth of cut= nominal depth of cut/ sin (principal cutting edge angle)
=2/sin (75)
=2.07mm
d) Chip reduction coefficient= chip thickness/ uncut layer thickness
= 0.4/0.193
=2.072mm
e) Cutting ratio=1/ chip reduction coefficient
=1/2.072
=0.482
f) tan(shear angle)=(cos(back rake))/(chip reduction coefficient sin(back rake))
tan(shear angle) =cos(8)/(2.072-sin(8))
shear angle=27.11o

Ex 2:
The chip from an orthogonal cutting operation with

an uncut chip thickness of 0.2 mm for various rake

angles are:

(degree)
t (mm)

15

10

0.45

0.5

0.63

1.13

Calculate, for each chip, the corresponding shear

angle and shear strain and plot them against

Ex 3
The cutting and thrust components of the machining

force during orthogonal machining of aluminium with

a rake angle of 10 are found to be 312 N and 185
N, respectively.
i) Estimate the coefficient of friction between tool and
chip.
ii) If the rake angle is reduced to 0 , keeping all other
parameters the same, and if the coefficient of
friction also remains unchanged, estimate the new
values of Fc and F, using Merchants first
solution.

Ex:4
A turning

operation on mild steel has been

performed by a single point cutting tool having
normal rake angle 100. The width of cut and the
uncut thickness are 2.0 mm and 0.2 mm
respectively. The average value of the coefficient of
friction between the tool and chip is 0.5 and the
shear stress of the workpiece material is 400 N/mm2.
Estimate the cutting force, thrust force, shear force
and friction force components during the operation.

Ans:

Thanks