Mechanics of Metal cutting

Book: Manufacturing Technology, Volume 2,

By
P.N. Rao, McGraw Hill Education (India)
Private Limited.
 Machine tools
A power driven machine that performs a cutting
operation, including grinding
• Functions in machining:
– Hold work-piece
– Position tool relative to the work
– Provides power at speed, feed, and depth of cut
• The term also applied to machines that
perform metal forming operations

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 Important parameters of machining

1. Thickness of uncut layer

2. Chip thickness
3. Inclination of the face of the tool with respect to
the vertical to the cutting velocity
4. The relative velocity of the work and the cutting
tool

• Clearance angle between the work and the flank

surface make the cutting possible

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Cutting ratio

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Shear angle

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 Compute shear angle
● Uncut chip thickness = 2 mm, chip thickness = 2 mm and
rake angle = 0°.
● Uncut chip thickness = 1 mm, chip thickness = 2 mm and
rake angle = 0°.
● Uncut chip thickness = 2 mm, chip thickness = 2 mm and
rake angle = 45°.
● Uncut chip thickness = 2 mm, chip thickness = 2 mm and
rake angle = 30°.
● Uncut chip thickness = 1 mm, chip thickness = 2 mm and
rake angle = 30°.
● Uncut chip thickness = 2 mm, chip thickness = 2 mm and
rake angle = 60°.
● Uncut chip thickness = 1 mm, chip thickness = 2 mm and
rake angle = 60°.
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Shear strain (γ)

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 Compute shear strain
● Uncut chip thickness = 2 mm, chip thickness = 2 mm and
rake angle = 0°.
● Uncut chip thickness = 1 mm, chip thickness = 2 mm and
rake angle = 0°.
● Uncut chip thickness = 2 mm, chip thickness = 2 mm and
rake angle = 45°.
● Uncut chip thickness = 2 mm, chip thickness = 2 mm and
rake angle = 30°.
● Uncut chip thickness = 1 mm, chip thickness = 2 mm and
rake angle = 30°.
● Uncut chip thickness = 2 mm, chip thickness = 2 mm and
rake angle = 60°.
● Uncut chip thickness = 1 mm, chip thickness = 2 mm and
rake angle = 60°.
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 Mechanics of chip formation
• First proposed by Ernst and Merchant
– Trans. ASME, 29, 299, 1941.
– Considered idealized case of a single plane
– An approximate is predicted
– Forces (F, N) on chip from rake face = Forces (Fs, Fn) on
work along shear plane = Forces (Fc, Ft) on tool
• Forces on tool:
– Fc - along the direction of cutting velocity
– Ft - Perpendicular to cutting velocity

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 Evaluate
1. In a cutting process cutting force and its
component are found to be equal with
magnitude = 250 N. If the rake angle is zero,
evaluate the friction angle.
2. Let cutting force = 400 N, force perpendicular
to it = 100 N and rake angle = 0O. Find the
coefficient of friction between the tool and
work material.

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 Wok done

Where as t1, w, τs, λ, α and vc are constant.

For minimum power, differentiate W w.r.t φ and
equating to zero, we get

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Shear angle relations

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Velocity relationship

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Using sine rule

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Specific energy

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Single point Cutting Tools

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Multipoint Cutting Tools

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Nomenclature of a single
point cutting tool

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Signature of right hand single point
cutting tool

10-20-7-6-8-15-1/32 (0.8)

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Rake angle

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Oblique cutting

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 Orthogonal turning
• For orthogonal cutting, the signature of right
hand turning tool should possess the following
components:
a) End rake angle = zero
b) Side cutting edge angle = zero
c) Uncut chip thickness (t1) << width of cut (w)
(For 2-D cutting)

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 Problem
• Suggest a signature of a right hand turning tool for
orthogonal cutting during turning. Justify.
• Give the effective rake angle when plain turning is
done with a right hand turning tool with the
signature as 0-10-6-7-25-0-1/64. Give reasons for
your answer.
• In an orthogonal turning of a 50 mm cylindrical
rod, the feed, depth of cut and speed are 0.2
mm/rev, 2 mm, and 200 rpm respectively.
Estimate uncut chip thickness, width of cut and
average cutting velocity.

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F.W. Taylor (1907), tool life equation

Where
V = cutting velocity
T = tool life (minute, mm, number etc.)
n = exponent, depends up on
C = a constant, depends up on cutting conditions
Modified or general equation of tool life, where
d = depth of cut
f = feed

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 Problem
• Tool needs regrinding after producing 400
small components at the speed of 400 rpm.
When the speed is doubled the production
between two consecutive regrinding is
reduced to 100 components. Compute the
amount of production between two
consecutive regrinding when speed is reduced
to 200 rpm.

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 Types of tool wear
• Crater wear
• Flank wear
• Chipping or
catastrophic failure

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 Crater wear
• Temperature
– diffusion
• Degree of chemical
affinity

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 Flank wear
• Sliding of the tool along
the machined surface
– Adhesive and/or
abrasive wear
• Temperature rise

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 Chipping or catastrophic failure
Breaking away of a piece from the edge of the
cutting tool
• Mechanical shock
• Thermal fatigue
• Occurrence
– A small crack /defect already exists
– High positive rake angle
– Crater wear

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Catastrophic failure of tool
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 Metal removal rate
MRR = dfVc = πDavgdfN
Where
Vc = cutting velocity
Davg = average diameter, mm
d = depth of cut, mm
f = feed, mm/rev
N = speed, rpm

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Machining time, T
(Turning/boring)

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Tool material

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Properties of cutting tool material
• Hardness at elevated temperature
– Hot hardness
• Toughness
• Wear resistance
• Surface finish of the tool
• Chemical inertness with respect to work
material
• Thermal conductivity
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Cutting tool material

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Cont..........

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Stellite

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Cemented carbides

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Cemented carbides

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Ceramics

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Ceramics

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Cubic boron nitride(CBN) and synthetic
diamond

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Cutting fluids

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Desirable properties

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Types of cutting fluid

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Straight cutting oils

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Types of straight cutting fluids

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Inactive cutting fluids

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Inactive cutting fluids

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Active cutting fluids

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Active straight cutting oils

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Emulsions

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Emulsions

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Chemical fluids

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Economics of metal cutting

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Cutting parameters

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Important parameters to optimize

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Production cost

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Machining cost

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Tool changing cost

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Tooling cost

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THANKS
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