Theory of metal cutting

Introduction
1) Metal cutting is the process of removing a layer of metal from blank to obtain a machine part of the required shape and dimensions and with the specified quality of surface finish. In order to remove material from the blank the cutting tool should be harder than the material to be cut and the tool should be strong enough to withstand the forces developed during cutting process. The metal cutting process is accompanied by deformation due to compression, tension and shear and by great deal of friction and heat generation. There are two basic types of processes used to shape metals: CHIP REMOVAL PROCESS eg. Turning, Shaping, Drilling, Milling, Grinding, Boring, Honing. During the metal cutting process there is a relative motion between the workpiece and the cutting tool. This relative motion is produced by a combination of rotary and translatory motions of the tool or the workpieceor both. Operation Turning Milling Shaping Drilling Motion of the workpiece Rotary Translatory Fixed Fixed Motion of the cutting tool Translatory Rotary Translatory Rotary as well as Translatory

2)

CHIPLESS PROCESS eg. Rolling, Forging, Spinning, Stamping

Mechanics of chip formation

Wedge-shaped tool is made to move relative to workpiece. As the tool makes contact with the metal, it exerts pressure on the metal resulting in the compression of the metal near the tool tip. Under this compressive force (cutting force) the material of the workpiece is stressed beyond its yield point causing the material to deform plastically and shear off in the form of chips. The plastic flow takes place in a localised region called as shear plane which extends obliquely upto the uncut surface ahead of the tool. The sheared material (chips) begins to flow along the cutting tool face causing its wear. Heat is produced during shearing action. The temperature rise in the cutting tool leads to its softening and loss of keenness leading to its failure. The cutting force, heat and abrasive wear are the basic features of metal cutting process. The tool material should be hard, strong, tough and wear resistant.

Basic elements of machining

1) Cutting Tool 2) Workpiece 3) Chip Workpiece provides parent material from which unwanted material is removed in the form of chips by the cutting action of the tool to obtain desired shape, size and surface finish Two distinct methods to produce surfaces by machine tools are: 1) Generating- Workpiece rotates around an axis and the tool moves parallel to the axis. 2) Forming- The work is stationary and the cutting tool moves in the direction of the axis of cylinder

Classification of cutting Tools:

1) Single point cutting tool Only one cutting edge is present. Commonly used in lathes, shapers, planers, slotting and boring machines. They are subdivided into: a) Ground type b) Forged Type c) Tipped type d) Bit Type Multi point cutting Tools They have more than one cutting edge. Commonly used in drilling machines, milling machines, reamers, grinding machines and broaches.

2)

Different types of cutting tools

Single point cutting tool

Multi point cutting tool

Single point cutting tool

A single point cutting tool consists of a sharpened cutting part called as point and the shank. The point is bounded by the face (along which the chips slide as they are cut by the tool), the side flank or the major flank , the end flank or the minor flank and the base. The cutting edge a-b formed by the intersection of the face and the major flank is called as side or major cutting edge. The cutting edge c-a formed by the intersection of the face and the minor flank is called as end or minor cutting edge. The chips are cut from the workpiece by the side cutting edge. The pont of intersection of side and end cutting edges is called as the nose. The intersection of flank and base of the tool is called as heel. A single point cutting tool may be right handed or left handed cutting tool based on the direction of the feed.

Principle surfaces and planes in metal cutting

Right handed tools- Tool moves from right to left Left handed tools- Tool moves from left to right

Three types of surfaces in turning operation are: 1. Work surface The surface from which material is cut 2. Machined surface- The surface which is formed or generated after removal of chip 3. Cutting surface - The surface which is formed by the side cutting edge of the tool The references from which tool angles are specified are the cutting plane and basic planes Cutting plane - Plane tangent to the cutting surface and containing and passing through side cutting edge Basic plane- Plane normal to the longitudinal axis of the workpiece and which is parallel to longitudinal and cross feeds

Designation of cutting tools

1) American Standard Association (ASA) or American National Standard Institute (ANSI) system 2) Orthogonal Rake System (ORS) ASA system- Angles of the tool face are defined in two orthogonal planes one parallel and another perpendiicular to the tool axis . Both planes are perpendicular to the base of the tool.

Tool geometry: Single point cutting tool (right handed)

Tool designation in ASA system: BRA- SRA- ERA- SRA-ECEA-SCEA- Nose radius

Types of metal cutting process

Orthogonal cutting Cutting edge of the tool remains normal to the tool feed. Only two component of the cutting forces act on the tool. The direction of the chip flow velocity is normal to the cutting edge. The cutting edge clears the width of the workpiece on either ends. Oblique cutting - Cutting edge of the tool remains inclined at an acute angle to the direction of the tool feed. Three mutually perpendicular components of the cutting forces act on the tool. The direction of the chip flow velocity is at an angle with the normal to the cutting edge of the tool. The cutting edge may or may not clear the width of the workpiece on either ends.