LM5
LM5
LM5
Manufacturing Processes - II
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Indian Institute of Technology Delhi
Instructional objectives :
To enable the students, at the end of this lecture,
(i) describe with illustration the mechanism of
chip formation in machining
• ductile materials and
• brittle materials
(ii) describe geom. characteristics of ductile chips
• chip reduction coefficient & cutting ratio
• shear angle and cutting strain
(iii) Identify the causes, characteristics and effects
of built – up – edge (BUE) formation.
(iv) Classify chips and identify the conditions.
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• work material
• cutting tool – material and geometry
• levels of the process parameters
• application of cutting fluid
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Mechanism of chip formation in machining
ductile materials
a1: chip thickness (before cut)
a2: chip thickness (after cut)
Vf
Work
F
Tool N
R
o
VC
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Chip formation in machining brittle materials
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( o )
e 2
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VC'
• shear angle, o a1
Shear plane
A
B
o
a2
(o - o)
O o
C
AC = a2 = OAcos(o-o) VC
o
AB = a1 = OAsino
cos o r cos o
tan o
sin o 1 r sin o
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Y
O
M
o
N
P s shear strain
Y
o
PN NM PN NM
ON ON ON
cot o tan( o o ) 12
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• characteristics of BUE
Shape, size and bond strength of BUE depends on:
• work – tool materials
• tool geometry
• stress and temperature
• cutting fluid application
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(iv)Types of chips & condns. favouring those chip forms
Type of chips conditions
Work Cutting Feed Rake CF
matl. Vel. VC so angle,
1.discont. type
• irregular absent/
size & shape Brittle
inadeq.
• regular Ductile medium large - ve
size & shape but hard
2. cont. type Duct.&soft high low + ve profuse
• without BUE
Duct. medium med. / absent/
• with BUE large inadeq
&sticky
3. Jointed type Semi low / med. / - ve abs./
ductile medium large inadeq.
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A. Quiz test
Identify the correct one out of the four given answers
1. In turning mild steel the value of will be
(a) > 1.0
(b) < 1.0
(c) = 1.0
(d) none of the above
2. The value of shear angle, o depends upon
(a) tool rake angle
(b) friction at chip-tool interface
(c) built – up – edge formation
(d) all of the above
(contd.) 17
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B. Numerical problem
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Answers
A. Quiz Test
1 – (a)
2 – (d)
3 – (c)
4 – (b)
B. Numerical Problem
a2 a2 0.5
2.5
a1 so sin 0.2x sin 90o
cos o cos 0o
tan o [ 0 o
]
and sin o 2.5 sin 0 o o
1 1
0 .4
2 .5
o tan 1(0.4) 21.8o
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THANK YOU
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