Metal

Machining

ME 482 - Manufacturing Systems

Objectives
Objectives

Introduce
Introduce cutting
cutting terminology
terminology and
and principles
principles
Review
Review modern
modern machining
machining technologies
technologies and
and new
new methods
methods
(papers)
(papers)
Introduce
Introduce cutting
cutting parameters
parameters
Develop
Develop cutting
cutting models
models
Analyze
Analyze aa cutting
cutting example
example

ME 482 - Manufacturing Systems

Machining
Machining types
types
Turning
Turning
Drilling
Drilling
Milling
Milling
Shaping
Shaping
Planing
Planing
Broaching
Broaching
ME 482 - Manufacturing Systems

Machining tools
Single
Single point
point

Multiple
Multiple point
point

ME 482 - Manufacturing Systems

Machining tool materials

Most
Most modern
modern cutting
cutting tool
tool materials
materials are
are aa matrix
matrix of
of
materials
materials designed
designed to
to be
be very
very hard.
hard. These
These materials
materials will
will be
be
covered
covered in
in the
the next
next chapter.
chapter.

ME 482 - Manufacturing Systems

Machining surface finish

ME 482 - Manufacturing Systems

Machining terminology
Speed
Speed surface
surface cutting
cutting speed
speed (v)
(v)
Feed
Feed advance
advance of
of tool
tool through
through the
the part
part (f)
(f)
Depth
Depth of
of cut
cut depth
depth of
of tool
tool into
into part
part (d)
(d)
Rake
Rake face
face tools
tools leading
leading edge
edge
Rake
Rake angle
angle slant
slant angle
angle of
of tools
tools
leading
leading edge
edge ()
()
Flank
Flank following
following edge
edge of
of cutting
cutting tool
tool
Relief
Relief angle
angle angle
angle of
of tools
tools following
following edge
edge above
above part
part
surface
ME 482 - surface
Manufacturing
Systems

Machining terminology (cont.)

ls

Chip thickness thickness of machined chip

(tcc ) model
Orthogonal
Depth of cut = too
Shear plane length measured along shear plane chip (lss )
Chip width (not shown) width of machined chip (w )
Shear angle angle of shearing surface measured from tool
direction ()
ME 482 - Manufacturing Systems

Cutting conditions
Note: - Primary
Primary cutting
cutting due to
to speed
speed
- Lateral
Lateral motion
motion of
of tool
tool is
is feed
feed
- Tool penetration
penetration is
is depth
depth of
of cut
cut
The three together form the material removal rate (MRR):
MRR
MRR == vv ff dd
with units of (in/min)(in/rev)(in) = in33/min/rev
/min/rev

(or
(or vol/min-rev)

Types of cuts:
Roughing: feeds
feeds of
of 0.015
0.015 0.05
0.05 in/revdepths
in/revdepths of
of 0.1
0.1 0.75
0.75 in
in
Finishing: feeds
feeds of
of 0.005
0.005 0.015
0.015 in/rev
in/rev
ME 482 - Manufacturing Systems

depths
depths of
of 0.03
0.03 0.075
0.075 in
in

Cutting geometry
Chip thickness ratio = r = to / tc
From the shear plane geometry:
r = ls sin/[ls cos(-)]
which can be arranged to get
tan = r cos /[1 r sin]

ME 482 - Manufacturing Systems

Obviously, the
assumed failure
mode is shearing of
the work along the
shear plane.

Cutting geometry
Note from the triangles in (c) that the shear strain () can be
estimated as
= AC/BD = (DC + AD)/BD = tan(- ) + cot

Thus, if know
r and can
determine ,
and given
and , can
determine .
ME 482 - Manufacturing Systems

Cutting forces
Since R = R = R, we can get the force balance equations:
F = Fc sin + Ftt cos

F = friction force; N = normal to chip force

N = Fcc cos - Ftt sin

Fcc = cutting force; Ftt = thrust force

Fss = Fcc cos - Ftt sin Fss = shear force; Fnn = normal to shear plane force
Fnn = Fcc sin + Ftt cos

Forces are presented as function of

Fcc and Ftt because these can be
measured.

Friction angle =
tan= = F/N
Shear plane stress:
= Fss/Ass
where
Ass = too w/sin

ME 482 - Manufacturing Systems

Cutting forces given shear strength

Letting S = shear strength, we can derive the following
equations for the cutting and thrust forces*:
Fs = S As
Fc = Fs cos (cos (
Ft = Fs sin (cos (
* The other forces can be determined from the equations on the previous
slide.
ME 482 - Manufacturing Systems

Merchant equations
The
Merchant
reln
is a function of
Combining the equations from
the
previous
slides:
and . Where did these variables
= (Fc cos - Ft sin tow/sin
come from? Merchant eqn

The most likely shear angle will minimize the energy. Applying
Answer - Although the Merchant
d/d = 0 gives:
eqn is not shown as a direct function
of and
, these reln
enter from the
Merchant
equations for Fc and Ft from the
What does the Merchant relation
indicate?
previous
slide!

= 45 +

If we increase the shear angle, we

- increase in friction angle decreases

decrease shear
the toolangle
force and power
requirements!
- increase in rake angle increases shear
angle
ME 482 - Manufacturing Systems

Cutting models
The orthogonal model for turning approximates the complex
shearing process:
to = feed (f)
w = depth of cut (d)

ME 482 - Manufacturing Systems

Cutting power
Power is force times speed:
P = Fc v

(ft-lb/min)

The cutting horsepower is

hpc = Fc v/33,000 (hp)
The unit horsepower is
hpu = hpc/MRR

units?

Due to efficiency losses (E about 90%), the gross hp is

hpg = hpc/E
ME 482 - Manufacturing Systems

Cutting energy
Specific energy is
U = Fc v/(v tow) = Fc /(tow)

(in-lb/in3)

The table shown contains power and specific energy ratings for several work materials
at a chip thickness of 0.01 in. For other chip thicknesses, apply the figure to get a
correction factor multiply U by correction factor for thickness different than 0.01).

ME 482 - Manufacturing Systems

Machining example
In orthogonal machining the tool has rake angle 10, chip thickness before
cut is to = 0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting
and thrust forces are measured at Fc = 350 lb and Ft = 285 lb while at a
cutting speed of 200 ft/min. Determine the machining shear strain, shear
stress, and cutting horsepower.
Solution (shear strain):
Determine r = 0.02/0.045 = 0.444
Determine shear plane angle from tan = r cos /[1 r sin]
tan = 0.444 cos /[1 0.444 sin] => = 25.4
Now calculate shear strain from = tan(-) + cot
= tan(25.4 - 10) + cot 25.4 = 2.386 in/in
ME 482 - Manufacturing Systems

answer!

Machining example (cont.)

In orthogonal machining the tool has rake angle 10, chip thickness before
cut is to = 0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting
and thrust forces are measured at Fc = 350 lb and Ft = 285 lb while at a
cutting speed of 200 ft/min. Determine the machining shear strain, shear
stress, and cutting horsepower.
Solution (shear stress):
Determine shear force from Fs = Fc cos - Ft sin
Fs = 350 cos 25.4 - 285 sin 25.4 = 194 lb
Determine shear plane area from As = to w/sin
As = (0.02) (0.125)/sin= 0.00583 in2
The shear stress is

= 194/0.00583 = 33,276 lb/in2

ME 482 - Manufacturing
Systems

answer!

Machining example (cont.)

In orthogonal machining the tool has rake angle 10, chip thickness before
cut is to = 0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting
and thrust forces are measured at Fc = 350 lb and Ft = 285 lb while at a
cutting speed of 200 ft/min. Determine the machining shear strain, shear
stress, and cutting horsepower.

Solution (cutting horsepower):

Determine cutting hp from hpc = Fc v/33,000
hpc = (350) (200)/33,000 = 2.12 hp
ME 482 - Manufacturing Systems

answer!

Cutting temperatures
In machining 98% of the cutting energy is converted into heat. This
energy flows into the work part, chip, and tool. Cook determined an
experimental equation for predicting the temperature rise at the
tool-chip interface during machining:
T = 0.4 U (v to/K)

/( c)

0.333

where

Example in text calculates

T = 936 total tool
temperature, given v =
200 ft/min, c = 120 in-lb/
(in3- F) and K = 0.125
in2/s

T = mean temperature rise (F)

U = specific energy (in-lb/in3)
v = cutting speed (in/s)
to = chip thickness before cut (in)
c= volumetric specific heat of the work material (in-lb/(in 3-F))
= thermal diffusivity of the work material (in 2/s)

Note - To get total temperature at tool-chip interface, must add in ambient

ME 482 - Manufacturing Systems

Cutters
Toroid

ME 482 - Manufacturing Systems

Cutters

ME 482 - Manufacturing Systems

Machining

What did we learn?

ME 482 - Manufacturing Systems