CHAPTER CONTENTS

65
5 FUNDAMENTALS OF METAL CUTTING
5.1 Overview of Machining
5.2 Mechanics of Machining
5.3 Cutting Forces
5.4 Cutting Temperature
5.5 Tool Wear and Tool Life
5.6 Cutting fuids
5.7 Surface Finish
5.8 Cutting Tool Materials
5.9 Machinability
5.10 Selection of Cutting Conditions
5.1 OVERVIEW OF MACHINING
Defnitions
v Machining: term applied to all material-removal processes
v Metal cutting: the process in which a thin layer of excess metal (chip) is removed by a
wedge-shaped single-point or multipoint cutting tool with defned geometry from a
workpiece, through a process of extensive plastic deformation
work surface
chip
cutting tool
feed motion
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machined
surface
Close-up view of a turning operation in
which a thin layer of metal (chip) is
removed from the work surface of a rotating
workpiece by a coated cemented carbide
cutting tool. The newly generated surface
is referred to as a machined surface. Cutting
process requires both primary and feed
motions.
direction of primary motion
direction of
feed motion
workpiece
chip
tool
cut
work surface
machined surface
Schematics of metal cutting process showing the basic
terminology.
Overview of Machining 66 Valery Marinov, Manufacturing Technology
v Abrasive processes: material removal by the action of hard, abrasive particles that are
usually in the form of a bonded wheel. Each single particle acts like a single-point
cutting tool. Since the particular geometry of a particle is not known, abrasive processes
are referred to as machining with geometrically undefned tools
v Non-traditional processes: machining with electrical, optical or chemical sources of
energy
Set-up of the grinding operation showing
the workpiece, abrasive bonded wheel and
the spray of burned chips
Cutting operation performed
by a fve-axis CO
2
laser
The place of machining operations
Metallurgical processes
Casting Metal forming Powder metallurgy
Material-removal processes
Assembly
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Diagram showing the place of machining operations within the entire production cycle.
Machining operations are capable of producing more precise dimensions and smooth surface fnishes
than all other manufacturing processes. They are performed after other processes, which create the
general shape of the parts. Machining then provides the fnal geometry, dimensions and fnish.