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MECHANICS OF
METAL CUTTING
Prof. Dr. S. Engin KILI
MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II
Content
Kalpakjian-Schmid,
2008
Orthogonal Cutting
Oblique Cutting
(a)
MFGE 307
II
6
Secondary
motion
Cutting
motion
Feed
motion
Cutting
speed
Feed rate
Depth of cut
adjustment
Depth of cut
Chip Formation
Chip Formation
10
Continuous Chip
Discontinuous Chip
Machining brittle
materials
Small rake angle
Large depth of cut
Machining ductile
materials at
Serrated Chip
Occurs in machining
ductile materials with
high friction at toolchip interface
Chip welds to tool face
Destroys accuracy and
surface finish
Increases tool wear
Can be reduced by
Cutting Forces
a0
ac
c u ttin g
to o l
Fs
Fc
Fn
Ft
Fr
Ff
c u ttin g
to o l
plane
Fr: resultant force
shear angle
15
Cutting Forces
F 2 r Fc2 Ft 2 Fs2 Fn2s Fn2 F f2
tan( - n ) =
Ft
Fc
Fs Fc cos - Ft sin
Fns Fc sin Ft cos
F f Fc sin n + Ft cos n
Fn Fc cos n - Ft sin n
Ff
=
= tan
Fn
MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II
16
sin cos n
ac
sin cos n
a0
ac
rc
a0
rc cos n
tan
1 rc sin n
MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II
17
Theoretical Models
Fs Fr cos n
s Ac
Fs s As
sin
MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II
20
s Ac
1
Fc
0 to minimize Fc
sin cos n
Fc Fr cos n
2 n
s Ac cos n
2
Fc
sin cos n
Fr
21
Stress
Strain
22
Assumptions (Contd)
24
Lee-Shaffer Theory
(Contd)
max
2
2 = 90o
Fr
45o
1
=
45o
45o
90o n
Hence,
n
w = v.f.d
d
where,
w: metal removal rate
v: cutting speed
f
f
f: feed rate
cutting conditions
d: depth of cut
Ac: f.d = undeformed chip cross sectional
area
ac = f cos
Side Cutting Edge Angle
MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II
26
Power Requirement
E: Energy required to remove unit volume of
chips
or
Resistance to cutting force
GJ
E 3 or GPa
m
GJ GN m GN
m 3 m 3 m 2 GPa
Power Requirement
Power Requirement
Power required at the spindle:
E = Eo . (ac )
=>
so
ac
where ac = f . cos
Power Requirement
Power Requirement
31
Power Requirement
EXAMPLE:
For an orthogonal cutting operation where v= 36 m/min f= 0.25 mm/rev it was found E
= 3.8 (W-sec/mm3) (m/min). If the power available at the spindle = 5 hp, find the
maximum metal removal rate and corresponding depth of cut. Note that 1 hp = 746 W.
Power 5 x746
w
E
3.8
mm 3
W
982
W
s
3
mm
N m
5 x746
Power
s 6216 N
F
36 m
v
60 s
mm 3
982
s
w
6.55mm
vf 36 x103 mm
x0.25mm
60 s
Problem 1
In an orthogonal cutting test on mild steel, the following results
were obtained:
ac= 0.25 mm
a0= 0.75 mm
d = 2.5 mm
Fc = 900N
Ft = 450N
n = 100
Problem 2
For an orthogonal turning operation it was found that
power consumption of lathe when idle
= 325 W
power consumption of lathe when cutting = 2580 W
For the following conditions:
spindle speed, N = 124 rpm;
cutting speed, v = 24.5 m/min
depth of cut, d = 3.8 mm;
feed rate, f = 0.2 mm/rev
Find:
a) specific cutting energy of the work material,
b) torque at the spindle,
c) cutting force,
d) specific cutting energy for 1 mm undeformed chip thickness
assuming = 0.4.
MFGE 307 THEORY OF MANUFACTURING TECHNOLOGY II
35
Problem 3
25 mm holes will be drilled on a steel workpiece, having a
hardness of Rc=45 {specific cutting energy, E = 77 W/(cm3/min)}
using an HSS twist drill at the following conditions:
cutting speed, v = 24.5 m/min
feed rate, f = 0.2mm/rev
Find:
a) the motor power if the efficiency of the transmission is 85%,
b) torque required.