Manufacturing Technology-II

Lecture 4 – Methods and Mechanics of

Metal cutting

Subject:19MEE215- Manufacturing Technology-II

Class: III Sem B.Tech –Mechanical
 Methods of Metal cutting
The Basic Methods of metal cutting

Orthogonal Cutting or 2D cutting

The cutting edge of the tool is perpendicular to the cutting velocity, the
process is called orthogonal cutting

Oblique Cutting or 3D cutting

The cutting edge of the tool is not perpendicular to the cutting velocity but
set an angle with the normal to the cutting velocity
Orthogonal/Oblique cutting
 Orthogonal and Oblique Cutting

Work
Work

Feed
Feed
Tool
Tool

Oblique cutting
Orthogonal cutting

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 Orthogonal Cutting Oblique Cutting
Difference between
orthogonal cutting and It is a 2-D (two force cutting It is a 3D (three force cutting system
system ie., cutting force and i.e., cutting force, radial force and
oblique cutting thurst force) thurst force or feed force)
The edge of the tool is The cutting edge is inclined at an
perpendicular to the line of angle (not equal to 900) to the feed
action (feed), hence path or tool travel.
perpendicular to the cutting
velocity vector
The chip flows directly over the The chip flows sideways, away from
tool face, and coils into a tight the tool face, and forms long and
flat spiral open curls
The direction of the chip flow is The direction of the chip flow is at an
normal to the cutting edge of the angle to the cutting edge of the tool.
tool The angle is known as chip flow
angle
For a given depth of cut and feed For a given depth of cut and feed the
the metal cutting force(shearing metal cutting force(shearing force)
force) acts on a smaller area of acts on a larger area of the tool and
the tool and requires smaller requires larger cutting forces
cutting forces
Friction is more and hence tool Tool life is more, since the heat
life is shorter developed /unit area on the tool due
to friction along the tool-work
interface
Orthogonal Cutting
Chip Formation in Oblique cutting

Fig: a) cutting with an oblique tool b) Top view showing the

inclination angle, i.
c) Types of chips produced with different inclination
 Forces acting on a cutting tool

The force system in general case of

conventional turning process

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Mechanics of Orthogonal Metal Cutting
 During metal cutting, the metal is severely compressed in the
area in front of the cutting tool. This causes high temperature
shear, and plastic flow if the metal is ductile.
 When the stress in the work piece just ahead of the cutting tool
reaches a value exceeding the ultimate strength of the metal,
particles will shear to form a chip element, which moves up
along the face of the work.
 The outward or shearing movement of each successive element is
arrested by work hardening and the movement transferred to the
next element. The process is repetitive and a continuous chip is
formed.
 The plane along which the element shears, is called shear plane.
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 Orthogonal Cutting Model
A simplified 2-D model of machining that describes the mechanics
of machining fairly accurately.
Major Variables in Orthogonal Cutting
 Chip Thickness Ratio

The ratio of to/tc is known as the cutting ratio, r, expressed as:

Where, r = chip thickness ratio;

to = thickness of the chip prior to chip formation; and
tc = chip thickness after separation 12
 Chip Thickness Ratio
 The outward flow of the metal causes the chip to be thicker after
the separation from the parent metal.
 i.e. the chip produced is thicker than the depth of cut, so chip
ratio always less than 1.0
 Chip compression ratio: reciprocal of r. It is a measure of how
thick the chip has become compared to the depth of cut.
 The chip thickness ratio is an important and useful parameter for
evaluating cutting conditions.
 Since the undeformed chip thickness, to is a machine setting and
is therefore known, the cutting ratio can be calculated easily by
measuring the chip thickness with a micrometer.
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 Chip Thickness Ratio

to ls sin  sin 
r  r
tc ls cos(   ) cos(   )

Rearranging: r cos 
tan  
1  r sin 
9/12/2006
 Determining Shear Plane Angle
Based on the geometric parameters of the orthogonal model, the
shear plane angle  can be determined as:
r cos 
tan  
1  r sin 
When shear angle is small
The plane of shear will be larger, chip is thicker and higher
force required to remove
where r =the chip.
chip ratio, and  = rake angle
When shear angle is large
The plane of shear will be shorter, chip is thinner and hence
lesser force required to remove the chip.
The shear angle is determined from chip thickness ratio.
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Lecture 4.3- Velocity Relationship in
Metal cutting

9/12/2006
 Velocity Relationship in Orthogonal Cutting
The tool has a rake angle of α, and relief (clearance) angle. The shearing process in
chip formation is similar to the motion of cards in a deck sliding against each other.

Figure (a) Schematic illustration of the basic mechanism of chip formation by shearing. (b)
Velocity diagram showing angular relationships among the three speeds in the cutting zone. 70
Velocity Relationship

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 Velocity Relationship
Using sine rule,
v v vs
 c 
sin(90  (   )) sin  sin(90   )
v vc vs
 
cos(   ) sin  cos 

vc  v  r v sin 
vc  v cos 
 Sin   cos(   ) vs 
r  Cos ( -  )  cos(   )
 
Volume of material per unit time  Volume of material flowing up the chip
 v  t0  w  vc  tc  w
t0
 vc  v  r As, r 
tc
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