Theory of Metal Cutting

Chapter – 4

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 Learning Objectives
• Importance of metal cutting
• Advantages & disadvantages of machining
• Mechanism of machining
• Operating conditions
• Thermal Aspects in machining
• Cutting fluids
• Types of chips
• Cutting tools (Types, Geometry, Materials )
• Tool life
• Machinability

2
 Manufacturing processes
• By melting material and pouring it into a
cavity of desired shape.
– (Casting)
• By moving material from one region to
another (0).
– (Forming)
• By putting materials together (+).
– (Joining)
• By removing unnecessary material (-).
– (Metal cutting) 3
 What is Metal Cutting
• It is a process of removing unnecessary
material from a workpiece in the form of
chips using a relative motion between the
workpiece and hard edge of a cutting tool
held against the workpiece.
• If workpiece is metal, then we call metal
cutting or else we use machining only.

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 Glossary
• Workpiece/Stock: The raw material from which
the unwanted material is removed.
• Cutting tool: The device or body used to
remove (cut) the unwanted material from the
workpiece.
• Chip: Removed unwanted material from the
workpiece.
• Machine tool: The machine which provide the
relative motion between the workpiece and the
cutting tool for machining to take place.
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 Applications of Machining
• Automobile
• Aerospace
• Home appliances
• Railway
• Ship building
• Consumer electronics etc.

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 Importance of Metal Cutting
• In U.S.A, the cost associated with the metal
cutting is approximately 10-15% of GDP.
• A majority (above 80 %) of machine tools
used in the manufacturing industry have
undergone machining.
• Machining in manufacturing industry
constitutes about 35% of all manufacturing
processes.

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 Advantages of Machining
Dimensional accuracy
surface finish
External and internal geometric features
Special surface texture
Economical, especially if the number of
parts to be produced is small.

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 Disadvantages of Machining
 Material wastage. In machining an
average workpiece about one half of the
material is removed from the workpiece
 Large amount of energy is expended and
much of this energy ends up as
undesirable heat
 If not carried out properly, machining can
have adverse affects on surface quality
and properties of the product
 Takes more time 9
 Functions of Machine tool
• Relative motion between the workpiece
and the cutting tool
• Hold the workpiece
• Hold the tool
• Supply energy

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 Specifications of Machine tool
• Shape of surface to be produced
• Size of workpiece
• Surface accuracy and smoothness
• Quantity

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 Machine tool Classification
• According to Degree of specialization
– General purpose machine tools
– Special purpose machine tools
• According to Type of surface produced
– Cylindrical surface producing machine tools
– Flat surface producing machine tools
– Irregular surface producing machine tools
• According to Type of motion
– Reciprocatory type of machine tools
– Rotary type of machine tools 12
Machine tool Classification (contd.)
• According to Degree of automation
– Manual machine tools
– Semi-automatic machine tools
– Automatic machine tools
• According to Duty cycle
– Light duty machine tools
– Medium duty machine tools
– Heavy duty machine tools
• According to Type of energy used
– Conventional
– Non conventional
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Mechanism of metal cutting

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 Operating Conditions
• Cutting speed
• Feed
• Depth of cut

• It influences material removal rate.

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 Cutting Speed
• Distance travelled by the work surface in a unit
time with reference to the cutting edge of the tool
• It is usually expressed in m/min.
• Cutting speed to be used depends upon
workpiece material, cutting tool material,
machining process, cutting fluid, machine tool
used, surface finish required and tool life.

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 Feed
• Distance advanced by the tool (assuming job
remains stationary) for each revolution of the
workpiece.
• It is usually expressed in mm/rev.
• Low feed produces fine surface finish.
• Feed to be used depends upon size of
workpiece, tool geometry, tool & workpiece
material, cutting fluid, cutting speed and depth of
cut

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 Depth of Cut
• Perpendicular distance between the
machined surface and the unmachined
surface or the previously machined surface.
• It is usually expressed in mm.

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 Material Removal Rate
• Amount of material removed in one minute.
• It is usually expressed in mm3/min.
• It influences the machining time
Machining Time:
• Time required to machine the material.

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 Thermal Aspects in Machining
• Temperature rises with the increase in
speed and thus tool strength decreases
• Excessive temperature adversely affects
the strength, hardness and wear
resistance of the cutting tool
• Increased heat causes dimensional
changes in the part being machined,
making it difficult to control dimensional
accuracy
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Thermal Aspects in Machining contd.
• The machine tool itself may be subjected
to elevated and uneven temperatures,
causing distortion of the machine tool and
therefore, poor dimensional control of the
workpiece.

• Machining at high speed is desirable for

higher productivity

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 Heat Generated/distribution
• Q = Q1 + Q2 + Q3 + Q4
– where
Q = Heat generated
Q1 = Heat taken away by the chips
Q2 = Heat conducted into the tool
Q3 = Heat conducted into the workpiece
Q4 = Heat dissipated to the surroundings

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 Heat Generated/distribution

Work 10%
Tool 10%
% Heat

Chips 80%

Cutting Speed v 23
 Cutting Fluids
• Functions of cutting fluids
– Provides lubrication
– Reduces heat generation
– Carries away the heat generated and hence
provide cooling effect
– Washes away chips

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25
 Types of chips
• Continuous chips
• Continuous chips with BUE
• Discontinuous chips
Built-up
Chip edge
Chip Tool

Workpiece
Continuous Discontinuous
chip chip 26
 Continuous chips
• Ductile material
• High cutting speed
• Large rake angle

• Chip breakers are used to break them.

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 Discontinuous chips

• Brittle workpiece material

• Low cutting speed.
• Small rake angle
• Low stiffness of the machine tool

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 Continuous chips with BUE
• Stronger adhesion between chips and tool
face.

• Poor surface finish

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 Cutting tools
• Cutting tool materials
• Cutting tool types
• Cutting tool geometry

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 Cutting Tool Types
• Single point cutting tools
• Multipoint cutting tools

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 Cutting Tool Types
• Right Hand Cutting Tool
• Left Hand Cutting Tool
• ?
Side cutting Side cutting
Edge Edge

 32
 Orthogonal Cutting

Relative
velocity of
workpiece
and cutting
tool is
perpendicular
to the cutting
edge
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Oblique Cutting
Relative
velocity of
workpiece
and cutting
tool is
perpendicular
to the cutting
edge
(inclined with by
an angle called
inclination angle)

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 Cutting Tool Geometry
• Defined by 6 angles and nose radius
– back rake,
– side rake,
– Clearance or end relief,
– side relief,
– end cutting edge angle,
– side cutting edge angle,
– nose radius.

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Right Hand Cutting Tool

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Side rake angle

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 Tool Signature

• (back rake, side rake, end relief, side

relief, end cutting edge angle, side cutting
edge angle, nose radius)
• 8 – 14 – 6 – 8 – 6 – 15 – 1/8

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 Tool Life
• time for which a tool can cut effectively or
it is the time between two successive re-
sharpenings of a cutting tool
• Calculated by using Taylor’s equation
VTn = C
Where, V = cutting speed; T = tool life;
n = slope of log T – log V curve;
C = constant depends on tool and work
material

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 Tool Life
Intercept (log C)
1
Slope (n)
log v 2

0 log T
log v1 log v2
n tan
log T1 log T2
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 Tool Life

Work material Tool material n C

HSS 0.1-0.16 160-190

Steel
Carbide 0.18-0.2 220-290

HSS 0.08-0.1 100-180

Cast Iron
Carbide 0.2-0.28 250-325

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 Tool Life
n n1 n2
vT f d C
1 2 3
v
log v
f
log f
log d
d

log T 42
 Factors Affecting Tool Life

• Process variables – speed, feed, depth of cut

• Tool material
• Tool geometry
• Workpiece material – hardness &
microstructure
• Cutting fluid

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 Machinability
• Defined as the ease or difficulty of machining
a material under a set of conditions.
• Defined in terms of various factors
– Surface finish of the part
– Tool life obtained
– Force and power requirements

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 Machinability Index
Vs = specific cutting speed to produce a tool life T
for standard material
Vt = specific cutting speed to produce a tool life T
for test material

Machinability = (Vt / Vs ) X 100 %

Machinabil ity Index

Cutting speed of the material for 20 minute tool life
100 %
Cutting speed of SAE 1112 steel for 20 minute tool life

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