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    Chip F

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    Abubeker desta

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    © All Rights Reserved
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    Chip F

    Uploaded by

    Abubeker desta
    5 views14 pages

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    Copyright:

    © All Rights Reserved
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    5 views14 pages

    Chip F

    Uploaded by

    Abubeker desta

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 14

    MANUFACTURING

    ENGINEERING II
    TRADITIONAL MACHINING
    Geometry of tool
    Cont..
    Chip formation
    Orthogonal cutting Oblique cutting

    the cutting edge is perpendicular to the direction of the cutting edge is not perpendicular to the direction
    cutting speed of cutting speed

    2 component of force Fc and Ft 3 component of force Fc, Fa and Fr

    2 dimensional cutting 3 dimensional cutting

    Eg parting, sawing ,broaching operations Part turning, drilling, milling, shaping operations
    Cont..

    Orthogonal cutting: (a) as a three-dimensional process, and (b) how it reduces to two dimensions in
    the side view
    The tool in orthogonal cutting has only two elements of geometry: (1) rake angle and
    (2) clearance angle. As indicated previously, the rake angle adetermines the direction that
    the chip flows as it is formed from the workpart; and the clearance angle provides a small
    clearance between the tool flank and the newly generated work surface.
    This corresponds to the thickness of the chip prior to chip
    formation,to. As the chip is formed along the shear plane, its thickness increases to tc.The ratio of to to tc is called
    the chip thickness ratio(or simply thechip ratio)r:
    Cont..

    • Since the chip thickness after cutting is always greater than the
    corresponding thickness before cutting, the chip ratio will always be
    less than 1.0
    .

    (a) chip formation depicted as a series of parallel plates sliding relative to each other; (b) one of the plates isolated to
    illustrate the definition of shear strain based on this parallel plate model; and (c) shear strain triangle used to derive
    which can be reduced to the following definition of shear strain in metal cutting:

    𝐴𝐶 𝐴𝐷+𝐷𝐶
    ϒ= 𝐵𝐷 = 𝐵𝐷
    ϒ = tan (φ-α) + cotφ
    Ex 1
    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 in. Calculate
    the shear plane angle and the shear strain in the operation.
    Solution: The chip thickness ratio can be determined
    0.5
    r= = 0.444
    1.125
    0.444 cos 10
    tanφ= =0.4738
    1−0.444𝑠𝑖𝑛10
    φ=25.4
    Types of chips
    1) Discontinuous chip
    - Hard and brittle material
    - Lower cutting speed, time is more ,Chip can be curl to the minimum
    radius, bending of chip will be maximum
    - Small rake angle, cutting force will be high
    - Larger depth of cut and feed
    - Use of cutting fluids
    . ) Continuous chip
    2
    Continuous chip with out BUE
    - ductile material
    - Cutting speed is high
    - Small feed and depth of cut
    - Large rake angle
    - Cutting fluid
    - Long continuous chips
    Continuous chip with BUE
    - Strong adhesion between the tool and workpiece material
    - Low cutting speed
    - Small rake angle
    - No cutting fluid
    Con..
    MERCHANT EQUATION
    • 𝐹 = μ𝑁
    • μ= tanβ
    𝐹𝑠
    • τ=
    𝐴𝑠
    𝑡𝑜 𝑤
    • 𝐴𝑠 =
    𝑠𝑖𝑛ϕ
    (a) forces acting on the chip in orthogonal cutting, and (b) forces acting
    on the tool that can be measured
    Force diagram showing
    geometric relationships
    Between Fs,Fn,Fc, andFt
    .
    Cont..
    Ex 2.Suppose in Example 1 that cutting force and thrust force are
    measured during an orthogonal cutting operation : Fc=1559 N and Ft
    =1271 N. The width of the orthogonal cutting operation w=3.0 mm.
    Based on these data, determine the shear strength of the work
    material.
    • Solution: From Example1, rake angle α =10, and shear plane angle
    φ =25.4

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