10-09-2015

VELOCITY RELATIONSHIP,
SHEAR STRESS & STRAIN,
CONSTRUCTION OF
MERCHANT CIRCLE

PLOUGHING FORCE
In the theoretical analysis, it is assumed
that the cutting edge is perfectly sharp.
The sharpness of the tool tip may be
further increased by grinding and
lapping.
However the tool edge has a finite
radius, however small it may be. Also,
just as the cut starts, the sharpened
cutting edge invariably loses some of the
sharpness due to impact and abrasion
etc. This small thickness (or radius) of the
cutting edge increases the cutting force.
If a graph between the cutting force
components and the depth of the cut is
drawn, it is found that they posses a
straight line relationship. However the
lines relating the two variables do not
pass through the origin. They make fine
positive intercepts on the force axis for
zero depth of cut.

10-09-2015

In experiments, the tool rake face is grinded to limit the length of contact between the
tool and chip and as a result we get a different line relating the force and depth of cut.
At zero depth of cut, all these lines intersect at a point on the force axis. This shows that
force value given by the intercepts are due to the radius of the tool at the tool edge. The
force components corresponding to the above intercepts are the components of the
ploughing force.
It is believed that on the tool edge, there is ploughing action, i.e. the material has to
flow over the radius of the tool edge. Therefore, the cutting force components Fh and Fv
are written as the sum of cutting and the ploughing force components.

Fh = Fhp + Fhc
Fv = Fvp + Fvc
where Fhp and Fvp are components due to the ploughing action of the tool edge and Fhc
and Fvc are components of cutting action.
Fhp and Fvp are taken equal to the intercepts at uncut chip thickness t = 0 in the
corresponding graphs. If the tool tip is assumed circular with radius r, the intercepts are
taken at t = r(1+sin) for obtaining the ploughing force components.

CHIP VELOCITY
During the machining operation, let us assume that the work material is
moving against the cutting tool with a velocity V.
The surface layer shears across the shear plane AC and becomes part of
the chip. That is, the surface layer suffers the velocity discontinuity
parallel to the shear plane.
The chip velocity Vc which acts along the tool rake face, is the vector sum
of the velocity of uncut chip (V) and the velocity discontinuity along the
shear plane (Vs).

10-09-2015

Applying the properties of triangle to OAC, we have

V
Vs
V
=
= c
sin (90 + ) sin (90 ) sin
The chip velocity Vc and shear velocity Vs may be obtained as

Vc =

V sin
cos( )

Vs =

V cos
cos( )

10-09-2015

10-09-2015

THANK YOU