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7/31/2019 BME-008_B-1(Unit_1)
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5
Metal Cutting and
Chip FormationUNIT 1 METAL CUTTING AND CHIP
FORMATION
Structure
1.1 IntroductionObjectives
1.2 Material Removal Processes1.3 Chip Formation
1.3.1 Deformation in Metal Machining1.3.2 Chip Types1.3.3 Types of Cutting1.3.4 Mechanics of Chip Formation1.3.5 Geometry of Chip Formation (Orthogonal Cutting)
1.4 Force Analysis1.5
Velocity Relationships
1.6 Shear Strain and Shear Strain Rate1.7 Shear Angle Relationships1.8 Summary1.9 Key Words1.10Answers to SAQs
1.1 INTRODUCTION
Manufacturing processes can be broadly divided into four categories, viz., primary(casting, forging, moulding, etc), secondary (machining, finishing, etc.), tertiary
(fabricating processes like welding, brazing, riveting, etc.), and fourth level processes
(painting, electroplating, etc.). Secondary manufacturing processes are as important as
any other level processes. These processes involve removal of material in the form of
chips or otherwise, to give the desired shape, size, surface roughness, and tolerance on
the workpiece obtained from the primary manufacturing processes. The machined
components can be used as it is, or one can be assembled (sometimes using fabricating
processes) and if required, given an aesthetic look by electroplating, painting, etc. This
block/unit will discuss the fundamentals of traditional material removal processes (non-
traditional material removal processes are discussed in Block 4). This unit will discuss
basic principles of metal cutting including mechanics of chip formation, velocity and
force analysis, and some of the models proposed to evaluate the shear angle relationships.
Objectives
After studying this unit, you should be able to
understand classification scheme for various types of material removal processes, identify various types of metal cutting processes, types of chip formed,
mechanism of chip formation and geometry of chips,
analyse forces and velocities in cutting process, and know various schools of thought regarding shear angle relationships.
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Theory of Metal Cutting 1.2 MATERIAL REMOVAL PROCESSES
Material removal processes can broadly be divided into two categories : traditional and
advanced (non-traditional). Each of these categories can be further sub-divided into bulk
removal processes (or cutting) and finishing processes. The classification of various types
of material removal processes is shown in Figure 1.1(a). This unit will discuss only the
basics of traditional cutting processes.
Traditional Cutting
Traditional cutting processes can be classified as those which produce parts having
surfaces of revolution and those which produce prismatic shapes. Another scheme
for the classification of metal cutting processes is provided in
Figure 1.1(a). This classification is based on the type of motion imparted to the
work and tool. Cutting tools used for material removal are classified in two
categories : single point cutting tool and multi-point cutting tool (cutting tools
having more than one cutting edge). The following section discusses how material
removal takes place by using a single point cutting tool. Similar principles are
applicable to the multiple point cutting tools as well.
Figure 1.1(a) : Classification of Material Removal Processes
The process of metal cutting is effected by providing relative motion between the
workpiece and the hard edge of cutting tool. Such relative motion is produced by a
combination of rotary and translating movements either of the workpiece or of the
cutting tool or both. Depending on the nature of the relative motion, metal cutting
process is called either turning or planning or boring, etc.
For different types of operations, one needs to have different types of machine
tools. For example, lathe for turning, planer for planning, grinder for grinding, etc.
Some of these machines (say, lathe, boring m/c, and drill) generate surfaces of
revolution whereas others (planer, milling m/c, and shaper) make prismatic (or flat
surfaces) parts. With the help of different types of tools, a lathe can perform
various kinds of operations (Figure 1.1(b)).
Conventionally, the translatory displacement of the cutting edge of the tool along
the work surface during a given period of time is called feed(f), while the
relative rate of traverse of work surface past the cutting edge is designated as the
cutting velocity or simply speed (Vc).
In case of single point turning, Vc is the peripheral velocity of the rotating
workpiece in meters per minute. In case of slab milling, it is the peripheral velocity
of the milling cutter in meters/minute.
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Metal Cutting and
Chip Formation
Figure 1.1(b) : Various Operations that can be Performed on a Lathe [Kalpakjian, 1989]
Table 1.1
Operation Motion of Job Motion of Cutting Tool Figure of Operation
Turning on a
lathe
Rotary motion of the
work
Axial movement of the tool
Boring on a
lathe
Work rotation Axial tool movement
Drilling on a
drill machine
Fixed Rotations as well as
translatory feed
Planning Translatory Intermittent Translation
Milling Translatory Rotation
Grinding Rotary/Translatory Rotary
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Theory of Metal Cutting 1.3 CHIP FORMATION
1.3.1 Deformation in Metal Machining
Figure 1.2 shows a schematic diagram of material deformation during cutting, and
subsequently removal of the deformed material from the workpiece by a single point
cutting tool. Because of the relative motion between the tool and the workpiece, material
ahead of the tool face (rake face) is compressed (elastically and then plastically). Further,movement of the tool into the workpiece deforms the work material plastically and
finally separates the deformed material from the workpiece. This separated material
flows on the rake face of the tool called as chip. The chip near the end of the rake face is
lifted away from the tool, and the resultant curvature of the chip is called chip curl.
Figure 1.2 : Schematic Diagram of Chip Deformation
The study of the mechanism of chip formation involves deformation process of the chip
ahead of the cutting tool. Theoretical study of the material deformation in metal cutting is
difficult and therefore experimental techniques have been resorted to for analyzing the
process of deformation in chips. The methods commonly employed for this purpose are :
(i) Use of movie camera for taking pictures of chip.(ii) Observing grid deformation during cutting.(iii) Examination of frozen chip samples obtained by the use of quick-stop
device.
Experimental study of chip deformation process has revealed that :
(i) During machining of ductile materials, a plastic deformation zone is formedin front of the cutting edge (Figure 1.2).
(ii) The distinctive zone of separation between the chip and workpiece wheredeformation gradually increases towards the cutting edge is called the
primary deformation/shear zone. In shear zone extensive deformation
occurs. The width of shear zone is very small.
(iii) The plastic deformation involved in the formation of chips affects thehardness of material (strain hardening). Strain hardening increases when a
layer undergoes deformation in the shear zone.
1.3.2 Chip Types
The type of chip obtained from a machining process is characterized by a number of
parameters e.g., the type of tool-work engagement, work material properties and the
cutting conditions.
Ernst has classified the chips obtained in machining processes into three categories :
Type 1 : Discontinuous chip,
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Metal Cutting and
Chip FormationType 2 : Continuous chip, and
Type 3 : Continuous with built-up edge.
When ductile materials at high cutting speed are cut by a single point cutting tool, ribbon
like continuous chip (Figure 1.3(a) and 1.3 (b)) is obtained. The conditions that promote
formation of continuous chips in metal cutting are sharp cutting edge, low feed rate (or
small chip thickness), large rake angle, ductile work material, high cutting speed, and low
friction at chip-tool interface. As shown in Figure 1.2, major deformation takes place inprimary shear deformation zone (PSDZ) resulting in the formation of chip. Due to ductile
nature of work material and reasonably high temperature in the PSDZ, the deforming
material flows on the rake face of the tool as continuous mass rather than the one
fractured/ruptured at small distances at the underneath of the chip as in discontinuous
chip.
Continuous chip results in good surface finish, high tool-life, and low power
consumption. But disposal of large coiled chips is a serious problem, for many industries
where tons of chips are produced every week. To get rid of this problem various types of
chip breakers are used which are in the form of step or groove on the rake face of the
tool (Figure 1.4). The chip strikes with this step/groove and gets broken in the form of
small segments. Disposal of such small chips is not a problem .
If the friction between tool and chip while machining ductile materials is high, some part
of the chip gets welded to the rake face of the tool near its cutting edge. The welded
material is extremely hard and its size keeps on increasing with time. Because of the
hardness of the adhered materials onto the cutting edge, it participates in cutting to a
certain extent. That is why it is named as built up edge (Figure 1.5). As the size of the
BUE grows larger, it becomes unstable and it breaks. Some part from the broken BUE is
carried away by the chip as well as on the machined surface (Figure 1.3).
Figure 1.3 : Different Kinds of Chips : (a) Continuous; (b) Photograph of Continuous Chip;
(c) Continuous Chip with Built Up Edge; and (d) Discontinuous Chip
The chip with the adhered parts of the BUE is known as continuous chip with BUE. The
adhered parts of the BUE on the machined surface make the machined surface rough, but
the BUE protects the actual cutting edge of the tool from wear. Thus, cutting with BUEenhances the tool life (or tool cuts longer before regrind).
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Theory of Metal Cutting
Figure 1.4 : Different Types of Chip Breakers
Figure 1.5 : Development of Built Up Edge [Rao, 2000]
Discontinuous or segmented chips are produced while machining brittle materials or
ductile materials at low speeds and high friction conditions. The basic difference between
the mechanism of formation of discontinuous chip and continuous chip is that, instead of
continuous shearing of the material ahead of the cutting tool, rupture occurs
intermittently producing segments of chip (Figures 1.3 and 1.6). These chips are smaller
in length hence easy to dispose off, and give good surface finish on the workpiece.
Discontinuous chips are formed when cutting brittle materials, or cutting ductile
materials at low speed, or cutting with tools of small rake angle.
(a) Tear Type (b) Shear Type
Figure 1.6 : Hypothesized Discontinuous Chip Formation [Rao, 2000]
1.3.3 Types of Cutting
Principally, there are two types of cutting :
(i) Orthogonal cutting, and(ii) Oblique cutting.
Orthogonal Cutting
Orthogonal cutting operation is the simplest type of cutting operation, in which
the cutting edge is straight, parallel to the original plane surface of the workpiece
and perpendicular to the direction of cutting, and in which the length of the cutting
edge is greater than the width of the chip removed (Figures 1.7(a) and (b)). This
orthogonal cutting is also known as Two Dimensional(2-D) Cutting. A few of the
cutting tools perform orthogonally, such as lathe cut-off tools (Figure 1.7(a)),
straight (not helical) milling cutters, broaches, etc.
In actual machining, majority of the cutting operations (turning, milling, etc.) are
three dimensional (3-D) in nature and are called as oblique cutting. In obliquecutting, the cutting edge of the tool is inclined to the line normal to the cutting
direction, and this angle is known as angle of obliquity. This is also called the
inclination angle, i (Figure 1.7(c)). Oblique cutting can be defined as the cutting
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Metal Cutting and
Chip Formationoperation in which the cutting edge is straight and parallel to the original surface of
the workpiece, but is not perpendicular to the cutting direction, being inclined to
it. An angle of interest in this case is the chip flow angle, c which is defined asthe angle measured in the plane of cutting face between the chip flow direction and
the normal to the cutting edge (Figure 1.7(c)). Both i and c are zero in case oforthogonal cutting. The certain practical limitations to orthogonal cutting are
mitigated by three dimensional tooling.
Figure 1.7 : (a); (b) Orthogonal Cutting System; and (c) Oblique Cutting System
Generally for the mathematical analysis of the mechanics of metal cutting, orthogonal
cutting is considered because it is simpler than the oblique cutting. The results so
obtained can be used for oblique cutting operations.
1.3.4 Mechanics of Chip Formation
Plastic deformation is the main factor that governs formation of chips. Initially,
researchers (Merchant and others) proposed that deformation of the material takes place
along a plane (called shear plane) just ahead of the cutting tool and runs up to free
surface of the workpiece (Figure 1.8(a)). Once the deforming material crosses the shearplane, it slides along the rake face of the tool due to the velocity of cutting tool (relative
motion between the tool and workpiece). This hypothesis of a shear plane is useful from
the analysis of metal cutting point of view but has theoretical drawbacks. Here, the
transition from the un-deformed to the deformed material takes place along a shear plane
by changing cutting velocity from Vc(velocity of tool with respect to workpiece) to Vf(chip velocity relative to the tool). For this change to take place, the acceleration across
the plane (plane thickness equal to zero) has to be infinite. This also applies to the
stress-gradient across the shear plane. Due to the above anomaly, researchers (Oxley and
others) experimentally studied the deformation zone by freezing the cutting process with
the help of a quick stop device. When they studied the deformed zone under a
microscope, they found that the deformation takes place within a finite zone (thin or thick
depending upon various governing parameters). This is called as primary shear
deformation zone (PSDZ) (Figures 1.8 (b) and (c)). They also found that under certain
machining conditions, deformation also takes place at the tool-chip interface
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(Figures 1.8 (b) and (c)). This deformation is known as secondary shear deformation
zone (SSDZ).
Theory of Metal Cutting
Figure 1.8 : (a) Shear Plane; (b) Primary and Secondary Shear Deformation Zone in Chip Formation;
and (c) Frozen Chip Obtained by a Quick Stop Device
1.3.5 Geometry of Chip Formation (Orthogonal Cutting)
Figure 1.9 shows a simple geometry of chip formation in case of continuous chip
(type 2). The uncut chip thickness tu (equal to feed in turning) is deformed to give chip
thickness tc which experiences two velocities Vf(chip sliding velocity) and Vs (shear
velocity) along the tool face and shear plane, respectively. From this geometry, it is
possible to calculate the shear angle () in terms of measurable or known quantities tu, tcand .
Figure 1.9 : Geometry of Continuous Chip Formation
From right angle triangles, ABC and ABD (BD is perpendicular to AD drawn from B),
AB =tu/ sin
Also, AB = tc/ sin (90 ()) = tc / cos ()
)(cos
sin
=
c
u
t
t
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Metal Cutting and
Chip Formationc
u
t
tis called chip thickness ratio or chip thickness coefficient (rc) which can be written
as
+
=sin
sinsincoscos1
cr
or, += sincoscot1 rr cc
or, = tan)sin1(cos cc rr
cos
tan1 sin
c
c
r
r
=
. . . (1.1)
To determine the shear plane angle () for a given cutting condition the chip thickness
ratio
=
c
uc
t
tr , should be known. But to determine tc with a micrometer is somewhat
inaccurate. Hence, an indirect approach to this problem is to assume that the density of
metal during the cutting process does not change. Hence, the volume of uncut chip is
equal to the volume of metal removed (or deformed chip). Since the width of chip (b) is
equal to the width of metal being cut (in orthogonal cutting), therefore :
btLtbL uucc = (volume constancy condition)
c c u uL t L t=
or,u
c
c
u
L
L
t
t=
ucc u
t Lr
t L= = c . . . (1.2)
where,Lc is length of chip, andLu is corresponding length of material removed from the
workpiece (or uncut chip length).Lc can be easily measured, and it (Lc/ Lu) will give
more accurate results than (tu/ tc) because of the difficulties and inaccuracies involved in
the measurement of thickness of the deformed chip (tc).
1.4 FORCE ANALYSIS
Let us analyse the forces acting on the chip in orthogonal cutting. These are shown in
Figure 1.10 (a) and are as follows : Force,Fs, is the resistance to shear of the metal in
forming the chip.Fsacts along the shear plane. Force,Fn, is normal to the shear plane
and is a backup force on the chip provided by the workpiece. ForceNacting on the chip
is normal to the cutting face of the tool and is provided by the tool. Force Fis frictional
resistance offered by the tool to the chip flow. The latter force acts downwards against
the motion of the chip as it slides upwards along the tool face.
Figure 1.10 (b) shows the free body diagram of the forces acting on the chip. Forces Fs
andFn are represented by the resultantR, andFandNare replaced by the resultantR'.
This means that only two combined forces are acting on the chip, i.e., R andR'. There are
external couples on the chip which curl it, and they may be negated in this approximateanalysis. If equilibrium is to exist when a body is acted upon by two forces, they must be
equal in magnitude, and be collinear. Hence,R andR' are equal in magnitude, opposite in
direction and collinear (Figure 1.10).
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Theory of Metal Cutting
Figure 1.10 : (a) Force Components Acting on a Chip; and (b) Free Body Diagram of a Chip
Figure 1.11 shows a composite diagram in which the two force triangles of
Figure 1.10, have been superimposed by placing the two equal forcesR andR'together.
Since the angle betweenFsandFn is a right angle, the intersection of these forces lies onthe circle with diameterR as shown. Also,FandNmay be replaced byR to form the
circle diagram (Figure 1.11).
Figure 1.11 : Force Circle Diagram
The horizontal cutting forceFc and vertical forceFtcan be measured in a machining
operation by the use of a force dynamometer. The electric strain gauge type of transducer
is used in the dynamometer. AfterFc andFtare determined, they can be laid off as in
Figure 1.11 and their resultant is the diameter of the circle. The rake angle can be laidoff, and the forcesFandNcan then be determined. The shear plane angle can bemeasured approximately from a photomicrograph or by measuring tc and tu,or length of
chip and corresponding length of unmachined chip (discussed elsewhere).From Figure 1.11, the following vector Eqs. can be written
'RFFFFR
NF'R
tcns
=+=+=
+=
Merchant represented various forces in a force circle diagram in which tool and reaction
forces have been assumed to be acting as concentrated at the tool point instead of their
actual points of application along the tool face and the shear plane. The circle has the
diameter equal toR (orR') passing through tool point.
AfterFc,Ft, and are known, all the component forces on the chip may be determined
from the geometry. For instance, the average stress on the shear plane can be determined
by using forceFs and the area of the shear plane. Another useful quantity is the
coefficient of friction () between the tool and chip. Using force circle diagram, it can be
shown that
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+= sincos ct FFF . . . (1.3) Metal Cutting andChip Formation
and, = sincos tc FFN . . . (1.4)
Then, the coefficient of friction () is calculated as
+===
sincos
sincostan
tc
ct
FF
FF
N
F . . .(1.5)
where, is the friction angle.
or,
+=
tan
tan
tc
ct
FF
FF . . . (1.6)
We can also write :
+=
=
tan
tantan
)(tan
1
1
tc
ct
FF
FF . . . (1.7)
From Figure 1.11, we get :
= sincos tcs FFF . . . (1.8)
+= sincos ctn FFF
)tan( += sn FF . . . (1.9)
Also, from Figure 1.11,
)(cos
)(cos
)(cos
)(cos
+
=
+=
=
s
c
s
c
F
F
RF
RF
or,)(cos
)(cos
+
= sc FF . . . (1.9(a))
Shear plane area is equal to :
=
sin
btA us . . . (1.10)
If be the shear strength of the work material, then,
=sin
btF us . . . (1.11)
Substituting in Eq.(1.9 (a)), we get
btF uc
)cos(
)cos(
sin +
= . . . (1.12)
hence,)cos(sin +
=
btR u . . . (1.12(a))
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From Figure 1.11,Theory of Metal Cutting
)(sin)(cossin
)sin(
+
=
=
bt
RF
u
t
(From Eq. 1.12(a)) . . . (1.13)
From Eqs. (1.12) and (1.13), we can write :
)(tan = F
F
c
t . . . (1.14)
From the above analysis, unknown forces in the force circle diagram and the value of
coefficient of friction can be calculated providedFc, Ft, , tu and tc are known measured.
During machining operations, chips are formed as a result of plastic deformation. Hence,
chips experience stresses and strains. At shear plane, two normal forces simultaneously
act, i.e.,FsandFn. Shear stress () can be found as
Mean shear stress
== sin)sincos(
)(u
tc
s
s
bt
FF
A
F
. . . (1.15)
Mean Normal stress ()u
cts
n
btFF
A
F +==
sin)sincos( . . . (1.16)
where,As = Shear plane area = /tb u sin .
1.5 VELOCITY RELATIONSHIPS
Since the chip is thicker than the uncut chip, the velocity of the chip as it moves along thetool face must be less than the cutting speed (assuming volume constancy during cutting,
and width of cut before machining and after machining remains same). Different
velocities during cutting can be estimated as follows :
Assume that the cutting velocity of the tool relative to the workpiece is Vcwhich is
known before hand. The chip slides along the cutting (rake) face of the tool with a
velocity relative to the tool equal to Vf(chip flow velocity). The newly cut chip elements
move relative to the workpiece along the shear plane with a velocity equal to Vs (shear
velocity). From the principle of kinematics that the relative velocity of two bodies (here
tool and chip) is equal to the vector difference between their velocities relative to the
reference body (the workpiece). Employing this principle, Figure 1.12 has been drawn.
Using sine rule, from ABC, we get :
)90(sinsin))(90(sin =
=
VV
V sfc . . . (1.17)
or,
=
= cossin)cos(
sfc VVV
The chip flow velocity along the tool rake face is given by
)(cos
sin
= cf
VV =Vc . rc . . . (1.18)
whereas the shear velocity Vsis obtained as :
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Metal Cutting and
Chip Formation)(cos
cos
= cs
VV . . . (1.19)
Figure 1.12 : Velocity Relationship
1.6 SHEAR STRAIN AND SHEAR STRAIN RATESince most practical cutting processes are geometrically complex, let us first study the
orthogonal machining and extend the theory of orthogonal cutting to more complicated
cutting process involving oblique cutting. Due to simplicity and fairly wide applications,
the continuous chip without BUE has been most extensively studied. There areconflicting evidences about the nature of the deformation zone in metal cutting. This has
led to two basic schools of thought in the approach to the analysis.
Many workers, such as Piispanen, Merchant, Kobayashi and Thomson have favoured the
thin plane model while Palmer and Oxley, and Okushima and Hitomi have based their
analysis on thick deformation region (Figure1.8). Experimental evidences indicate that
the thick zone model may describe the cutting process at low speeds, but at high speeds
most evidences indicate that a thin shear plane is approached. Thin zone model is more
useful in practical cutting and its analysis is simpler hence it has received more attention.
Thin Zone Model
Merchant developed an analysis based on the thin shear plane model. He made thefollowing assumptions :
The tool tip is sharp and no rubbing or ploughing occurs between the tooland the workpiece.
The deformation is two dimensional, i.e., no side spread. The stress on the shear plane is uniformly distributed. The resultant forceR on the chip applied at the shear plane is equal, opposite
and collinear to the forceR'applied to the chip at the tool-chip interface.
Strain and strain rate are determined as follows :
To derive an expression for shear strain, the deformation can be idealized as aprocess of block slip (or preferred slip planes), as shown in (Figure 1.13). Shear
strain () is defined as the deformation per unit length.
CD
DB
CD
AD
CD
AB
y
s+==
=
+= cot)(tan . . . (1.20)
+
=sin
cos
)(cos
)(sin
)(cossin)(coscossin)(sin
+=
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Theory of Metal Cutting
)(cossin
cos
)(cossin
)(cos
=+
=
or,)(cossin
cos
= . . . (1.21)
Figure 1.13 : Strain and Strain Rate in Orthogonal Cutting
Strain may also be expressed in terms of the shear velocity (Vs) and the chip velocity(Vf)
sin
=
s
c
V
V (from Eq.(1.19))
Therefore, shear strain rate ( ) in cutting is given by
yt
s
t
y
s
dt
d
=
=
=1&
y
V
y
V cs
==
)(cos
cos
. . . (1.22)
y is mean thickness of PSDZ .
1.7 SHEAR ANGLE RELATIONSHIPS
A number of attempts have been made to study the mechanics of cutting process. In
designing a metal cutting operation, it would be helpful to predict the position of the
shear plane (angle ). Attempts have been made to derive a fundamental relationship of
the shear plane angle in terms of rake angle () and friction angle (). Several theorieshave been proposed to establish a relationship between , and . Some of the theories
have been discussed below.
Ernst-Merchant derived a relationship using the minimum energy criterion, that is, the
shear plane is located where the least energy is required for shear. The derivation of
Ernst-Merchant equation is based on the following assumptions :
(i) cutting is orthogonal,(ii) the shear strength of the metal along the shear plane is independent of the
magnitude of compressive (normal) stress acting on that plane,
(iii) the chip is continuous type with no built up edge, and(iv) the energy of separation of chip elements is neglected and the minimum
energy criterion establishes the plane on which shearing deformation occurs.
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Metal Cutting and
Chip FormationAs the cutting progresses in the beginning, the cutting force (Fc) increases gradually, the
shear stress on various planes ahead of the tool also increases. However, the shear stress
will not be same on all the planes ahead of the tool because the shearing components of
the forces on the planes are not the same, nor is the extent of areas the same. On one of
the planes, however, the shear stress will be greater than on any other plane, and as Fcisfurther increased, the shear stress will reach the yield strength in shear of the material
being cut and plastic deformation will occur along that plane, thus forming the chip. The
cutting force required to cause shear deformation along that plane will then be the lowestcutting force.Once the shear deformation begins along one plane, the cutting forcecannot exceed that minimum value.
To determine shear-plane angle , express the cutting forceFc in terms of, differentiateit with respect to , equate the derivative to zero, and solve it for the angle as follows :
{ } )(cos)(cos
sin)(cos
)(cos
+
=
+
= bt
FFu
sc (Eq.1.12)
Here, except all other parameters can be taken as constant during machining (assumingthat no strain hardening takes place). It would give the condition for the minimum energy
if the derivative ofFc with respect to is equated to zero.0
)(cossin
)(sin)(coscos)(cos
22=
+
++=
bt
d
Fdu
c
Therefore, cos cos ( ) sin sin ( ) 0 + + =
or, cos (2 ) 0 + =
or, (2 )2
+ =
Hence, )(21
4= . . . (1.23)
where, , and are shear angle, friction angle and rake angle, respectively.
Eq. (1.23) indicates that the shear angle is a unique function of the tool rake angle andthe angle of friction in metal cutting.
Merchant further introduced a modification to this theory and assumed that the shear
strength of a polycrystalline metal is affected by temperature, rate of shear, shear strain
(plastic) and the stress acting normal to the shear plane. While it is known that the normal
compression stress on a plane does not affect the shear strength of a single crystal
however, the shear strength of polycrystalline material is affected. The modified Eq. is)(
2
1
2=
C . . . (1.24)where, C depends on the slope of the shear strength vs. compressive stress curve for the
given material. 'C' is also known as machining constant.In 1949, another approach to the analytical solution of the shear plane angle was made by
Lee and Shaffer. They assumed that the material being cut behaves as an ideal plastic
which does not strain harden. It was assumed that the shear plane coincides with the
direction of the maximum shear stress (Figure 1.14). Based on these assumptions, they
applied slip line field theory and derived the relationship given by Eq. (1.25).
)(4
+= . . . (1.25)
As a modification, later on Lee and Shaffer considered the effect of a small built up edge
or nose, and its effect on the stress field referred to above and arrived at an expression for
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Theory of Metal Cutting the shear angle () which included an additional angle , which depends on the size of
the built up edge,
++
= )(4
In 1952, Shaw, Cook and Finnie extended the Lee and Schaffer theory by further
analytical and experimental investigations, and arrived at the following relationship :
( )4 = + +
While deriving the above relation, they assumed that the shear plane is not a plane of
maximum shear. Here, is established by the analytical method and it is not constant. is the angle between the shear plane and the direction of the maximum shear stress. To
determine the value and sign of the , it is necessary to draw the Mohrs circle diagram.
Figure 1.14 : Shear Plane Model of Lee and Shaffer
Based on the experimental study of the mechanics of chip formation and the flow of
grains in the material during cutting, Palmer and Oxley observed that the deformation
does not take place along a plane, rather it takes place in a narrow wedge shaped zone.
But for analytical simplicity, it was considered as a parallel sided shear zone
(Figure 1.15).
Figure 1.15 : Shear Zone Model by Oxley
A further contribution towards the solution of this problem was made by R Hill in 1954,
who analyzed the state of stress at the shear zone, using a new principle On the limits set
by plastic yielding to the intensity of singularities of stress. But in 1959, Eggleston,
Herzog andThomsen tried to show by their test results that none of the three Eqs. (by
Ernst and Merchant, Lee and Shaffer, and Hill) was correct which implies that metal in
the shear zone under the existing conditions of stress, high rates of strain and elevated
temperature does not behave as ideal plastic solid. Since no single criterion is applicable
to the shear angle relationship in metal cutting, and since a satisfactory theory has not
been advanced at present to explain the experimental observations adequately, the
challenge exists for a closer solution to the problem of angle relationship. This problem is
so tedious because the complexity is created by the simultaneous presence of so manyvariables at a time, for example :
(i) plastic deformation,(ii) work hardening,
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Metal Cutting and
Chip Formation(iii) external and internal friction,(iv) temperature effect,(v) diffusion,(vi) oxidation, and(vii) local heating, etc.
Example 1.1
Show that in case of ideal orthogonal cutting operation the shear strain undergone
by the chip during its removal from the workpiece would be minimum if the chip
thickness ratio is 1.
Solution
In Figure 1.13 the shear strain in general and shear strain in cutting are shown.
Here, s is in the direction of force, y is in the direction to the force.
Shear strain in another term of interest is associated with the cutting process. The
shear strain is defined as
y
s
and hence in cutting (Figure 1.13),
tan ( ) cots AB AD DB
y CD CD CD
= = = + = +
We want the condition when should be minimum. Hence, differentiate withrespect to and equate the derivative equal to zero.
{ } 0cot)(tan =+
=
d
d
d
d
0)eccos()(sec22 =+
= 22 eccos)(sec
or, .)(cossin 22 =
Take the under root to both sides,
)(cossin =
or, )(cossin = . . . (A)
+= sinsincoscos
+= sincotcos1 . . . (B)
Question is that at the condition (A) whether the chip thickness ratio is 1 or not.
We know that chip thickness ratio is given by
)cos(
sin
==
c
uc
t
t
If, = 1,
then)(cos
sin1
=
. . . (C)sin cos ( ) =
By comparing Eqs. (A) and (C), we find that both are the same. Hence, it is proved
that shear strain will be minimum only when the chip thickness ratio is unity.
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Metal Cutting and
Chip Formation = 1.771
Example 1.3
A cylindrical bar has a blind hole of 15 mm diameter. Its face is being turned
(facing operation) from inner diameter to the outer periphery (Figure given below)
at a speed of 600 RPM, feed = 0.20 mm/rev., and depth of cut =1.0 mm. Calculate
the cutting speed (m/s) and total volume removed at the end of 15s.
Solution
Arrow in the figure shows the tool movement.
Revolution/second (Ns) = 600/60 = 10
To find,
(i) V15 = cutting speed at the end of 15 seconds of facing operation.(ii) 15V = volume of material removed at the end of 15 seconds.(i) Vt=
1000
tDs
where,Ns t= 15 10=150 rev.(# of revolutions made by the the workat the end of 15s)
Vt= cutting speed at time 't'
D = d+ 2f Ns t(Figure above)
D = Diameter of the workpiece at which the tool tip will be after thetime of machining =15s. In one revolution of the workpiece, the
diameter at which the tool will be cutting, will increase by 2f. (or in
one revolution the diameter to which the tool tip reaches is increased
by 2f).
where, f feed rate
15 15 (2 0.20 10 15)D = +
= 75 mm
1575 10
1000
V
=
V15 = 2.36 m/s
(ii) Volume of the material removed in 15s.
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Theory of Metal Cutting15V = total area machined depth of cut
=4
(D2d2) 1 mm3
=4
(752 152) 1
15V = 4241 mm3
Example 1.4
During orthogonal turning of a pipe of 100 mm diameter, the rake angle of the tool
was 20o. The ratio of the cutting force to feed force was 3.0.The feed rate, depth of
cut and chip thickness ratio were 0.275, 0.687 and 0.4 respectively. With the help
of a dynamometer, feed force was measured as 460 N. Workpiece was rotating at
450 revolution per minute. Determine chip velocity, shear strain, shear strain rate
and mean width of PSDZ.
Solution
We know from Eq.(1.12) that
=
=
+ sin)90sin()90sin(fsc
VVV
Vf = Vc)90(sin
sin
+
. . . (A)
Vs= Vc)90(sin
)90(sin
+
. . . (B)
But, we do not know the values of and Vc. They can be evaluated as follows :
tan =
sin1
cos
c
c
r
r
=20sin4.01
20cos4.0
= 0.436
= tan-10.436
= 23.54o . . . (C)
Vc = 1000
450100
1000
=
DN
Vc=141.37 m/min . . . (D)
Substitute the values of and Vcin Eqs.(A) and (B).
Vf =)54.232090(sin
54.23sin37.141
+
Vf = 56.56 m/min
Vs=
)53.232090(sin
)2090sin(37.141
+
Vs= 133.11 m/min
We also know,
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Metal Cutting and
Chip Formation = tan () + cot
= tan (23.54 20) + cot (23.54)
= 2.357
)(cot.
cos
=
ds
Vc . . . (E)
Here, we do not know the value ofds. Using Lee and Shaffers theory, ds can be
derived as [Jain and Pandey, 1980]
ds =)45(sin
)90(sin
sin22
1
++
f
=)54.252045(sin
)54.252090(sin
)54.25(sin
275.0.
22
1
+
+
ds 0.324 mm
Therefore, from Eq. (E)
=324.0
100037.141
)2053.23(cos
20cos
= 6830 s-1
Note that the shear strain rate in metal cutting is very high as compared to the one
obtained in classical deformation test.
Example 1.5
Prove that the specific cutting pressure in an ideal orthogonal cutting is given by
cot , provided 2 + = /2 holds good ( shear stress).
Solution
Specific cutting pressure = c
u
F
bt . . . (A)
From Eq. (1.12),
Fc=
sin
btu .)cos(
)cos(
+
. . . (B)
It is given that,
() + 2 = /2 . . . (C)
Substitute the value of () from (C) in (B),
Fc =)22/(cos
)22/(cos.
sin +
btu
=
sin
btu .
sin
2sin
Sp. cutting press =
sin
btu .
sin
2sin.
ubt
1
=
sinsin
cossin2
Sp. cutting press = 2 cot proved
Example 1.6
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Following data were recorded during orthogonal machining :Theory of Metal Cutting
Bar diameter = 40 mm, depth of cut = 0.125 mm, length of chip obtained
= 62.5 mm/rev, horizontal cutting force = 220 kgf, vertical cutting force = 85 kgf,
= 7, spindle speed = 500 RPM.
Find out friction angle, chip thickness ratio, shear angle, chip velocity and shear
velocity.
Solution
Chip thickness ratio =c
u
t
t=
uu
c
ll
l 50.62= . . . (A)
We know, undeformed chip length
lu = DNr
= 40 1
= 120.66 mm
From (A), rc= 62.5/120.66 = 0.479
rc = 0.479
From Eq. (1.1),
= tan1
sin1
cos
c
c
r
r
Substitute the values,
= tan1 526.0939.0
494.0
= 27.7
=
+
tan
tan
tc
ct
FF
FF(Eq. 1.7)
Substitute the values in the above equation
= 53.07tan85220
7tan22085o
+
= 28.12
Cutting velocity, Vc =1000DN
=1000
50040
Vc= 62.83 m/min
Vf = Vc)cos(
sin
= 62.83 935.0
465.0
Vf = 31.22 m/min.
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Metal Cutting and
Chip FormationVs = Vc )90(sin
)90(sin
+
)7.27790(sin
)790(sin83.62
+
=
Vs = 66.66 m/min.
SAQ 1
Write the most appropriate option from the given ones
(i) In actual practice, chip thickness ratio is
(a) > 1, (b) < 1, (c) = 1.
(ii) In oblique cutting, the number of forces that act on the tool are
(a) one, (b) two, (c) three, (d) none of these.
(iii) Which of the following is the chip removal process?
(a) rolling, (b) extruding, (c) die casting, (d) broaching, (e) none of these.(iv) Time taken to drill a hole through a 2.5 cm thick plate at 3000 RPM at a
feed rate 0.025 mm/rev. will be
(a) 20 s, (b) 10 s, (c) 40 s, (d) 50 s.
(v) Shear plane angle is the angle between
(a) shear plane and the cutting velocity vector, (b) shear plane and tool face,
(c) shear plane and horizontal plane, (d) rake face and vertical plane.
(vi) In orthogonal cutting, the cutting edge should be
(a) straight, (b) parallel to the original plane surface of the workpiece,
(c) normal to the direction of cutting, (d) all of these, (e) none of these.(vii) Continuous chip with BUE
(a) yields good surface finish, (b) yields poor surface finish, (c) has no effect
on surface roughness.
(viii) The ratio of cutting velocity to chip velocity is usually
(a) >1, (b)
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Theory of Metal Cutting 1.9 KEY WORDS
Chip : It is the material which is separated from the
workpiece when the tool moves into the
workpiece.
Primary Shear Deformation : Finite zone (thin or thick depending upon
Zone (PSDZ) various governing parameters) within which
deformation takes place.
Secondary Shear Deformation : Deformation which takes place at tool-chip
Zone (SSDZ) interface.
Orthogonal Cutting : Two dimensional (2-D) cutting in which cutting
edge is straight, parallel to the original plane
surface of the workpiece and perpendicular to the
direction of cutting.
Oblique Cutting : Cutting operations are 3-D in nature. In this type
cutting edge at the tool is inclined to the linenormal to the cutting direction.
1.10 ANSWERS TO SAQs
SAQ 1
(i) (b)(ii) (c)(iii) (d)(iv) (a)(v) (a)(vi) (d)(vii) (a)(viii) (b)
EXERCISES
Q 1. (i) Derive a relationship to calculate shear angle in terms of measurable/known
parameters.
(ii) Draw force circle diagram proposed by Merchant for orthogonal cutting
conditions showing different forces acting on tool, chip, and work system.
From the diagram, derive the expression for
(a) shearing force on the shear plane,(b) friction force on the tool face in terms of cutting force, thrust force,
rake angle, and shear angle.
(iii) Define orthogonal cutting. Draw Merchant's force circle diagram for the
orthogonal cutting.
(iv) Using the Figure in Q.1 (ii) (a), derive the expression for friction force.
What are the factors which affect the formation of different types of chip
obtained in cutting.
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Metal Cutting and
Chip Formation(v) Determine the condition when
= tan1 (rc)
where, is the shear angle and rc is the chip thickness ratio.
(Hint : in the original Eq., Substitute tan = rc) (Ans. = 0)
(vi) Determine the condition for which chip flow velocity is equal to the cutting
velocity, assuming = 0. (Ans. = 45o)
(vii) Find the ratio ofFc/ Ftfor an imaginary case of machining if = = /4.
Q 2. Mild steel rod is being turned at the speed of 27.3 m/min. Feed rate used is
0.25 mm/rev, and deformed chip thickness is equal to 0.30 mm. Rake angle and
shear angle of the tool are 20o
and 30o, respectively. Calculate the shear flow
velocity.
Q 3. For orthogonal cutting of a M.S. rod, the following data are obtained : width of
cut = 0.125'', feed = 0.007'' per rev., = 15o, = 30o, and machining constant,C = 70
o.The dynamic shear strength of the work material = 80000 lb/in
2.
CalculateFc andFt.
Q 4. During orthogonal cutting of a tube at 100 m/min, the tangential force
(in the direction of cutting velocity) measured by the 3-D dynamometer is
200 kgf, and the axial force is 100 kgf. Assume the rake angle as 10o. Calculate the
work in shearing the metal if the shear angle = 30o. Also, derive the velocity
relationship used.
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Theory of Metal CuttingBIBLIOGRAPHY
Armarego, E. J. A. and Brown, R. H. (1969), The Machining of Metals, Prentice Hall,
Englewood Cliffs, NJ.
Jain, V. K. and Pandey, P. C. (1980),An Analytical Approach to the Determination of
Mean Width of Primary Shear Deformation Zone (PSDZ) in Orthogonal Machining,
Proc. 4th
International Conference on Production Engineering, Tokyo, pp 434-438.
Kalpakjian, S. (1989),Manufacturing Engineering and Technology, Addison-Wesley
Publishing Co., New York.
Pandey, P. C. and Sing, C. K. (1998),Production Engineering Science, Standard
Publishers Distributors, Delhi.
Rao, P. N. (2000),Manufacturing Technology : Metal Cutting and Machine Tools, Tata
McGraw-Hill Publishing Co. Ltd., New Delhi.
Shaw, M. C. (1984),Metal Cutting Principles, Oxford, Clarendon Press.
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Metal Cutting and
Chip FormationTHEORY OF METAL CUTTING
This block comprises three units. In this block, we are going to discuss about the
fundamentals of traditional material removal processes. Non-conventional material
removal processes are discussed in the last block.
In Unit 1, traditional material removal processes have been classified. In this unit, basics
of chip formation has been discussed in details. This unit also discusses force analysis,velocity relationships, and shear strain.
Unit 2 gives the thermal aspects in metal cutting. During metal cutting large amount of
heat is produced which leads to high temperature resulting into high tool wear rate. In
this unit, measurement of temperature of tool, chip and workpiece has been studied in
detail.
Finally, Unit 3 deals with tool wear, tool life, machinability and tool material. In this
unit, different types of wear and criterion to evaluate tool life are discussed.
Machinability and methods to evaluate machinability have also been described.
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Theory of Metal Cutting
MACHINING TECHNOLOGY
Manufacturing Technology course provides learners with the sound knowledge of
conventional as well as non-conventional (advanced) manufacturing techniques. In
Manufacturing Technology, you have already studied the principles of metal casting,
metal forming, principles of metal cutting and welding technology. In Machining
Technology, you are going to be introduced with other manufacturing processes. The
main aim while manufacturing a component is to achieve the desired component with the
required quality in the most economical manner. This objective can be achieved only
when the manufacturer has acquired sufficient knowledge of manufacturing concepts like
principles of metal cutting, machining operations, abrasive machining processes and non-
conventional material removal processes. This course on Machining Technology
comprises four blocks.
Block 1 (Theory of Metal Cutting) comprises 3 units. In this block, fundamentals of
traditional material removal processes have been introduced. In Unit 1, concepts like
material removal processes, chip formation and force analysis have been discussed.
Unit 2 elaborates the thermal aspects of metal cutting processes. It gives a complete
understanding of thermal phenomenon in machining. It deals with theoretical and
experimental methods to evaluate temperature distribution in the tool, work andtool-work interface. In Unit 3, tool wear, tool life, machinability and tool materials have
been discussed.
The emphasis in Block 2 is on abrasive machining processes. Surface integrity in general,
and surface finish in particular of a finished component is very important. Abrasive
finishing and its working principles are well explained in Unit 4. This unit also deals with
the specifications of grinding wheels and its selection for the given workpiece
requirements. Various kinds of grinding operations (face grinding, surface grinding,
cut-off grinding and others) and the mechanics of grinding are elaborated in Unit 5. Apart
from grinding there are various other finishing processes like lapping, honing, and super-
finishing. The characteristics and working principles of these processes are dealt with in
Unit 6.
Block 3 has three units which discusses various surface finishing processes. Unit 7 deals
with the surface characteristics and product performance. In this unit, surface finish
parameters, their importance and different types of surfaces produced by machining have
been discussed. Unit 8 describes the conventional surface finishing processes like honing,
lapping, deburring etc. in detail. Last unit, i.e. Unit 9, discusses the
micro-machining processes like ion-beam machining, electron beam machining etc. in
detail.
Block 4 deals with non-conventional (or advanced) material removal processes. It
comprises four units. In the first unit of this block, these processes have been introduced
and classified in three major categories. Unit 11 of this block deals with mechanical
advanced machining processes, e.g. abrasive jet machining (AJM), ultrasonic machining(USM) and abrasive flow machining (AFM). Unit 12 introduces thermal processes like
laser beam machining (LBM), electric discharge machining (EDM) and allied processes.
In the last unit of this block, i.e. Unit 13, electrochemical machining (ECM) method has
been elaborated.