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    Mechanics of Metal Cutting

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    Ammad Nadeem
    This document discusses the mechanics of metal cutting. It covers heat generation zones during cutting, tool terminology, cutting geometry models, assumptions of the orthogonal cutting model, experimental determination of cutting ratio, shear plane length and angle, shear and cutting velocities, forces on the cutting tool and workpiece, stresses on the shear plane and tool rake face, power consumption and dissipation, and material removal rate calculation.

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    Mechanics of Metal Cutting

    Uploaded by

    Ammad Nadeem
    52 views33 pages
    This document discusses the mechanics of metal cutting. It covers heat generation zones during cutting, tool terminology, cutting geometry models, assumptions of the orthogonal cutting model, experimental determination of cutting ratio, shear plane length and angle, shear and cutting velocities, forces on the cutting tool and workpiece, stresses on the shear plane and tool rake face, power consumption and dissipation, and material removal rate calculation.

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    This document discusses the mechanics of metal cutting. It covers heat generation zones during cutting, tool terminology, cutting geometry models, assumptions of the orthogonal cutting model, experimental determination of cutting ratio, shear plane length and angle, shear and cutting velocities, forces on the cutting tool and workpiece, stresses on the shear plane and tool rake face, power consumption and dissipation, and material removal rate calculation.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    52 views33 pages

    Mechanics of Metal Cutting

    Uploaded by

    Ammad Nadeem
    This document discusses the mechanics of metal cutting. It covers heat generation zones during cutting, tool terminology, cutting geometry models, assumptions of the orthogonal cutting model, experimental determination of cutting ratio, shear plane length and angle, shear and cutting velocities, forces on the cutting tool and workpiece, stresses on the shear plane and tool rake face, power consumption and dissipation, and material removal rate calculation.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 33

    MECHANICS OF METAL CUTTING

    Elements of Metal Cutting


    Heat Generation Zones
    30% (Dependent on m)

    (Dependent on f) 60%

    Chip
    Tool

    Workpiece

    10%
    (Dependent on sharpness
    of tool)
    Tool Terminology
    Side Rake
    (SR), +
    Back
    Rake
    End Cutting (BR),+
    edge angle
    (ECEA)
    Turning
    Facing Cutting
    Cutting edge
    edge Nose
    Radius Side relief
    angle
    Side cutting
    edge angle
    (SCEA)
    Clearance or end
    relief angle
    Cutting Geometry
    Cutting Models

    Tool
    Tool

    workpiece
    workpiece

    ORTHOGONAL GEOMETRY OBLIQUE GEOMETRY


    Assumptions
    (Orthogonal Cutting Model)

     The cutting edge is a straight line extending perpendicular


    to the direction of motion, and it generates a plane surface
    as the work moves past it.
     The tool is perfectly sharp (no contact along the clearance
    face).
     The shearing surface is a plane extending upward from
    the cutting edge.
     The chip does not flow to either side
     The depth of cut/chip thickness is constant uniform
    relative velocity between work and tool
     Continuous chip, no built-up-edge (BUE)
    Experimental Determination of
    Cutting Ratio

    Lc Shear angle f may be obtained


    wc tc either from photo-micrographs
    or assume volume continuity
    t0 (no chip density change):
    L0
    w0

    Si nc e t 0w 0L 0 = t cw cL c and w 0=w c (e xp. e v i de nc e )

    t0 Lc
    Cutting ratio , r = =
    tc L0
    i.e. Measure length of chips (easier than thickness)
    Shear Plane Length
    and Angle f
    Chip

    tool
    (f-)
    B
    tc
    to f
    A
    Workpiece

    t0
    Shear plane length AB =
    sinf
    -1 rc os
    She ar pl ane angl e (f) = Tan
    1-rsi n
    or make an assumption, such as f adjusts to minimize
    0
    cutting force: f = 45 + /2 - /2 (Merchant)
    Shear Velocity
    Vc = Chip Velocity
    (Chip relative to tool)
    Velocities
    (Chip relative (2D Orthogonal
    to workpiece) V
    s V = Cutting Velocity Model)
    Chip
    (Tool relative to
    Tool
    workpiece)

    Workpiece
    Velocity Diagram
    Vc
    Vs

    From mass c onti nui ty: Vt o = V ct c
    si nf f-
    V c = Vr and V c = V
    c os(f-)
    90 - f f
    From the Velocity diagram:
    V
    c os
    Vs = V
    c os(f-)
    Forces on the Cutting Tool
    and the workpiece

     Importance: Stiffness of tool holder, stiffness of machine, and


    stiffness of workpiece must be sufficient to avoid significant
    deflections (dimensional accuracy and surface finish)
     Primary cause: Friction force of chip up rake face + Shearing
    force along shear plane
     Cutting speed does not effect tool forces much (friction forces
    decrease slightly as velocity increases; static friction is the
    greatest)
     The greater the depth of cut the greater the forces on the tool
     Using a coolant reduces the forces slightly but greatly
    increases tool life
    Stresses
    On the Shear plane:
    Fn Fnsinf
    Normal Stress = s = Normal Force / Area = =
    AB w tow
    Fs Fssinf
    Shear Stress = s = Shear Force / Area = =
    AB w tow
    Note: s = y = yield strength of the material in shear

    On the tool rake face:


    N
     = Normal Force / Area = (often assume tc = contact length)
    tc w
    F
     = Shear Force / Area =
    tc w
    Power
    •Power (or energy consumed per unit time) is the product of force and
    velocity. Power at the cutting spindle:
    Cutting Power Pc = FcV
    •Power is dissipated mainly in the shear zone and on the rake face:

    Power for Shearing Ps = FsV s


    Friction Power Pf = FV c
    •Actual Motor Power requirements will depend on machine efficiency
    E (%):
    Pc
    Motor Power Required = x 100
    E
    Material Removal Rate (MRR)
    Volume Removed
    Material Removal Rate (MRR) =
    Time
    Volume Removed = Lwto

    Time to move a distance L = L/V

    Lwto
    Therefore, MRR = = Vwto
    L/V

    MRR = Cutting velocity x width of cut x depth of cut

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