PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar Gill Smid

Metal-Cutting Technology
Section 8
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

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Metal Cutting Technology

Metals used in products must be machined efficiently to be economical Cutting metals efficiently requires
Knowledge of metal to be cut How cutting tool material and its shape will perform under various machining conditions

Many new cutting-tool materials introduced in last few decades

Improved machine construction, higher cutting speeds and increased productivity

PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar Gill Smid

Physics of Metal Cutting

Unit 27

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

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Objectives
Define the various terms that apply to metal cutting Explain the flow patterns of metal as it is cut Recognize the three types of chips produced from various metals

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How Metal Is Cut

Have used tools without understanding how metal is cut Prior thought held that metal ahead of cutting tool split (like ax splits wood) Since WWII, research conducted
Found metal compressed and flows up face of cutting tool Led to new cutting tools, speeds and feeds, cutting-tool angles and clearances and cutting fluids

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Metal-Cutting Terminology
Built-up edge
Layer of compressed metal which adheres to and piles up on face of cutting tool edge

Chip-tool interface
Portion of face of cutting tool on which chip slides as cut from metal
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

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Metal-Cutting Terminology
Crystal elongation
distortion of crystal structure of work material occurring during machining operation

Deformed zone
Area in which work material deformed during cutting

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Metal-Cutting Terminology
Plastic deformation
Deformation of work material occurring in shear zone during cutting action

Plastic flow
Flow of metal that occurs on shear plane (extends from cutting-tool edge to corner between chip and work surface)

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Metal-Cutting Terminology
Rupture
Tear that occurs when brittle materials are cut and chip breaks away from work surface

Shear angle or plane

Angle of area of material where plastic deformation occurs

Shear zone
Area where plastic deformation of metal occurs Along plane from cutting edge of tool to original work surface

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Plastic Flow of Metal

Study flat punches on ductile material
Stress pattern Direction of material flow Distortion created in metal Used blocks of photoelastic materials

Polarized light used to observe stress lines

Saw series of colored bands isochromatics

Tested three punch types: flat, narrowfaced, and knife-edge

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Flat Punch
Flat punch forced into block of photoelastic material
Lines of constant maximum shear stress appear Isochromatics (shape of stress lines)
Appear as family of curves almost passing through corners of flat punch Greatest concentration occurs at each corner of punch Larger circular stress lines appear farther away from punch Spacing relatively wide

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Narrow-Faced Punch
Narrow-faced punch forced into block of photoelastic material
Stress lines concentrated
Punch corners Where punch meets top surface of work

Isochromatics spaced closer than with flat punch

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Knife-Edge Punch
Knife-edge punch forced into block of photoelastic material
Isochromatics becomes series of circles tangent to the two faces of punch Flow of material occurs upward from point toward free area along faces of punch

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When Cutting Tool Engages Workpiece

Internal stresses are created Compression occurs in work material because of forces exerted by cutting tool Concentration of stresses causes chip to shear from material and flow along chip-tool interface
Since most metals ductile to some degree, plastic flow occurs
Determines type of chip produced

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Chip Types
Machining operations performed on lathes, milling machines, or similar machine tools produce ships of three basic types

Discontinuous (segmented) chip

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

Continuous chip

Continuous chip with built-up edge

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Type 1 - Discontinuous (Segmented) Chip

Produced when brittle metals are cut Point of cutting tool contacts metal some compression occurs and chip begins to flow More cutting action produces more stress, metal compresses until rupture, and chip separates from unmachined portion Poor surface created
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

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Production of Type 1 Discontinuous Chip

Conditions that favor the production
Brittle work material Small rake angle on the cutting tool Large chip thickness (coarse feed) Low cutting speed

Excessive machine chatter

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Type 2 Continuous Chip

Continuous ribbon produced when flow of metal next to tool face not retarded by builtup edge or friction Ideal for efficient cutting action Results in better surface finishes Plastic flow as deformed metal slides on great number of crystallographic slip planes
No fractures or ruptures occur due to ductile nature

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Direction of Crystal Elongation Tool

As Cutting action progresses, metal ahead of tool is compressed with resultant deformation (elongation) of crystal structure.

Shear Angle

Plane of Shear
Shear Zone

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Conditions Favorable to Producing Type 2 Chip

Ductile work material Small chip thickness (relatively fine feeds) Sharp cutting-tool edge Large rake angle on cutting tool High cutting speeds Cutting tool and work kept cool using cutting fluids

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Conditions Favorable to Producing Type 2 Chip

Minimum resistance to chip flow
High polish on cutting-tool face Use of cutting fluids Use of cutting-tool materials which have low coefficient of friction
Cemented carbides

Free-machining materials
Those alloyed with lead, phosphor, and sulphur

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Type 3 - Continuous Chip with Built-Up Edge

Low-carbon machine steel and high-carbon alloyed steels Tool Low cutting speed with high-speed steel cutting tool chip Without use of cutting fluids Poor surface finish Built-up
Edge
Finished Surface of Work

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Type 3 Continuous Chip with Built-Up Edge

Small particles of metal adhere to edge of tool
Build-up increases until becomes unstable and breaks off Portions stick to both chip and workpiece Buildup and breakdown occur rapidly during cutting action

Shortens cutting-tool life

Fragments of build-up edge abrade tool flank Cratering effect caused short distance back from cutting edge where chip contacts tool face