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Chapter 5 Merchants Theory

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31 views18 pages

Chapter 5 Merchants Theory

Uploaded by

chapiab02
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Chapter Five

Merchants Theory

By Tantigegn K.

4/24/2024 1
Forces in metal cutting
Forces in metal cutting:

4/24/2024 2
Forces in metal cutting

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Forces in metal cutting

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Forces in metal cutting
Resultant forces:
 R' (Resultant force): is the vector addition of the two forces, Fs and
Fn.
 Force on the chip will be balanced if this resultant force is equal in
magnitude, opposite in direction and collinear with the resultant, R.

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Forces in metal cutting
 Force diagram representing relationship between F, N,
𝑭𝒔 , 𝑭𝒏 , 𝑭𝒄 , and 𝑭𝒕 :
 All these force components can’t be directly measured since the
directions in which they are applied vary with tool geometries and
cutting conditions.

fig. (b) Fig.(a)


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Forces in metal cutting
 Cutting force (𝑭𝒄 ) and thrust force (𝑭𝒕 ) are the two additional force
components acting against the tool. (Fig b)

 Cutting force (𝑭𝒄 ): is in the direction of cutting, the same direction


as the cutting speed, v.

 Thrust force (𝑭𝒕 ): is perpendicular to the cutting force and is


associated with the chip thickness before the cut, t0.

 R'' is the resultant of these two forces.

 These components can be directly measured by using a


dynamometer (force measuring device).

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Forces in metal cutting

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Forces in metal cutting

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Forces in metal cutting
The Merchant Equation:
 It is based on the assumption of orthogonal cutting.
 Shear stress:
According to Merchant;
 Out of all possible angles emanating from the cutting edge of
the tool at which shear deformation could occur, there is one
angle, , that predominates.”
 This is the angle at which shear stress is just equal to the shear
strength of the work material and so shear deformation occurs at
this angle.
 For all possible angles, the shear stress is less than the shear
strength of the work material. In effect, the work material will
select a shear plane angle that minimizes energy.
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Forces in metal cutting
The Merchant Equation:
 How this angle is determined?
 Take the derivative of the shear stress with respect to and set it to
zero,

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Forces in metal cutting
The Merchant Equation:

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Forces in metal cutting
The Merchant Equation:
 The shear plane angle can be increased by:
 Increasing the rake angle by proper tool design.
 Decreasing the friction angle (and coefficient of friction) between the
tool and the chip by using a lubricant cutting fluid.
 Keeping other factors the same, a
higher shear plane angle results in
a smaller shear plane area
(fig a) and smaller shear plane
angle results in large shear
plane area (fig b).

Fig.(a)

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Forces in metal cutting
 The shear force required to form the chip will decreases when the
shear plane area is reduced.
 A greater shear plane angle results in lower cutting energy, lower
power requirements, and lower cutting temperature.
 Therefore, these are good reasons to make the shear plane angle as
large as possible during machining.

Fig.(b)
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Approximation of turning by orthogonal cutting

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Power and Energy in machining

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Power and Energy in machining

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Thank you!

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