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Lecture 3 - Theory of Chip Formation in Metal Machining

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39 views37 pages

Lecture 3 - Theory of Chip Formation in Metal Machining

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kudzaishemakotore
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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THEORY OF METAL MACHINING

1. Overview of Machining Technology


2. Theory of Chip Formation in Metal Machining
3. Force Relationships
4. Power and Energy Relationships in Machining
5. Cutting Temperature
Material Removal Processes

 A family of shaping operations, the common feature of


which is removal of material from a starting work part so the
remaining part has the desired geometry
 Machining – material removal by a sharp cutting tool,
e.g., turning, milling, drilling
 Abrasive processes – material removal by hard, abrasive
particles, e.g., grinding
 Nontraditional processes - various energy forms other
than sharp cutting tool to remove material
The family tree
of material
removal
processes
Why Machining is Important

 Variety of work materials can be machined


 Most frequently used to cut metals
 Variety of part shapes and special geometric
features possible:
 Screw threads
 Accurate round holes
 Very straight edges and surfaces
 Good dimensional accuracy and surface finish
Disadvantages of Machining

 Wasteful of material
 Chips generated in machining are wasted material
 At least in the unit operation
 Time consuming
 A machining operation generally takes longer to
shape a given part than alternative shaping
processes
Machining in the Manufacturing
Sequence

 Generally performed after other basic manufacturing


processes, such as casting, forging, and bar drawing
 Other processes create the general shape of the
starting work part
 Machining provides the final shape, dimensions,
finish, and special geometric details that other
processes cannot create
Machining Operations

 Most important machining operations:


 Turning
 Drilling
 Milling
 Other machining operations:
 Shaping and planing
 Broaching
 Sawing
Turning

 Single point cutting tool removes material from a


rotating workpiece to form a cylindrical shape
Drilling

 Used to create a round


hole, usually by means
of a rotating tool (drill bit)
with two cutting edges
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Milling

 Rotating multiple-cutting-edge tool is moved across


work to cut a plane or straight surface
 Two forms: peripheral milling (left) and face milling
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Cutting Tool Classification

1. Single-Point Tools
 One dominant cutting edge
 Point is usually rounded to form a nose radius
 Turning uses single point tools
2. Multiple Cutting Edge Tools
 More than one cutting edge
 Motion relative to work achieved by rotating
 Drilling and milling use rotating multiple cutting
edge tools
Cutting Tools

 (a) Single-point tool showing rake face, flank, and tool


point; and (b) a helical milling cutter, representative of
tools with multiple cutting edges
Cutting Conditions in Machining

 Three dimensions of a machining process


 Cutting speed v – primary motion
 Feed f – secondary motion
 Depth of cut d – penetration of tool below original
work surface
 For certain operations (e.g., turning), material
removal rate RMR can be computed as
RMR = v f d
Cutting Conditions in Turning

 Speed, feed, and depth of cut in a turning operation


Roughing vs. Finishing Cuts

 In production, several roughing cuts are usually taken


on a part, followed by one or two finishing cuts
 Roughing - removes large amounts of material
from starting work part
 Some material remains for finish cutting
 High feeds and depths, low speeds
 Finishing - completes part geometry
 Final dimensions, tolerances, and finish
 Low feeds and depths, high cutting speeds
Machining

 Cutting action involves shear deformation of work material to


form a chip, and as chip is removed, new surface is exposed:
(a) positive and (b) negative rake tools
Orthogonal Cutting Model

 Simplified 2-D model of machining that describes the


mechanics of machining fairly accurately
Chip Thickness Ratio

to
r 
tc

where r = chip thickness ratio; to = thickness of the


chip prior to chip formation; and tc = chip thickness
after separation
 Chip thickness after cut is always greater than
before, so chip ratio is always less than 1.0
Determining Shear Plane Angle

 Based on the geometric parameters of the orthogonal


model, the shear plane angle  can be determined
as:
r cos 
tan  
1  r sin

where r = chip ratio, and  = rake angle


Shear Strain in Chip Formation

 (a) Chip formation depicted as a series of parallel plates sliding


relative to each other, (b) one of the plates isolated to show shear
strain, and (c) shear strain triangle used to derive strain equation
Shear Strain

 Shear strain in machining can be computed from


the following equation, based on the preceding
parallel plate model
 = tan( - ) + cot 
where  = shear strain,  = shear plane angle,
and  = rake angle of cutting tool
Actual Chip Formation

 More realistic view


of chip formation,
showing shear zone
rather than shear
plane
 Also shown is the
secondary shear
zone resulting from
tool-chip friction
Four Basic Types of Chip in
Machining

1. Discontinuous chip
2. Continuous chip
3. Continuous chip with Built-up Edge (BUE)
4. Serrated chip
Discontinuous Chip
 Brittle work materials
 Low cutting speeds
 Large feed and depth of
cut
 High tool-chip friction
Optics and Lasers in Engineering, Volume 49, Issue 2,
February 2011, Pages 240–247
Continuous Chip
 Ductile work materials
 High cutting speeds
 Small feeds and depths
 Sharp cutting edge
 Low tool-chip friction
Continuous with BUE

 Ductile materials
 Low-to-medium cutting
speeds
 Tool-chip friction causes
portions of chip to adhere to
rake face
 BUE forms, then breaks off,
cyclically
Springerimages.com
Serrated Chip
(springerimages.com)

 Semi-continuous - saw-
tooth appearance
 Cyclical chip forms with
alternating high shear strain
then low shear strain
 Associated with difficult-to-
machine metals at high
cutting speeds
Forces Acting on Chip

 (a) Friction force F and Normal force to friction N


 (b) Shear force Fs and Normal force to shear Fn
Resultant Forces

 Vector addition of F and N = resultant R


 Vector addition of Fs and Fn = resultant R'
 Forces acting on the chip must be in balance:
 R' must be equal in magnitude to R
 R’ must be opposite in direction to R
 R’ must be collinear with R
Coefficient of Friction

 Coefficient of friction between tool and chip


F

N
 Friction angle related to coefficient of friction as

  tan 
Shear Stress

 Shear stress acting along the shear plane

Fs

As
where As = area of the shear plane
t ow
As 
sin 
 Shear stress  = shear strength S of work material
during cutting
Practice Question

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Group Discussion Question

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Take Home

 "But they who wait for the Lord shall renew their
strength; they shall mount up with wings like eagles;
they shall run and not be weary; they shall walk and
not faint." - Isaiah 40:31

©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e

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