03-08-2015

ORTHOGONAL CUTTING
PART-II

STRESS DISTRIBUTION ON RAKE FACE IN

ORTHOGONAL CUTTING
In the analysis of orthogonal cutting, it has been assumed that the shear
and normal stresses are uniformly distributed over the tool rake face. It
has been proved experimentally that this assumption is not true. Both the
stresses are found to be varying along the contact length.

It is extremely difficult to determine the stress distribution on the tool rake

face in normal cutting operations, because of the very small contact
length, high cutting temperature and high values of normal and tangential
stresses involved.

In earlier attempts, the tools made out of a photo-elastic material and

workpiece made of soft metals like lead, tin and lead alloys were used. The
stress distribution on the rake face was determined by analysing the fringe
pattern observed during experimental cutting on photo-elastic apparatus.
The distribution is explained in the following figure 1.

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Figure 1

In another experiment, a tool made of two parts was used. The two parts were
mounted on separate force measuring instruments and the two parts together
made up the rake force. While cutting a given workpiece, the force is transmitted
to the two dynamometers were noted.

A portion of the tool near the cutting edge was ground off, thus changing the ratio
of contact length on the two parts during cutting. The difference between the two
sets of observations gave the values of stresses on the length equal to that ground
off the rake face. After repeated experiments, the stresses on differential lengths
all along the contact length could be determined.

Many investigators have approximated the distribution of normal stress on

the rake face by an exponential curve shown in figure 2. The shear stress is
assumed to be constant up to a certain portion of contact length from the
tool tip which is called sticking zone.

Beyond this zone, the shear stress decreases to zero exponentially. In this
zone, called the slipping zone, Coulombs law of friction is considered to
be applicable.

Figure 2

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The distribution function for the normal stress may be taken of the type
n = A.x m
Where A and m are constants and x is the distance measured from the
end of chip tool contact. Let max be the maximum value of normal stress
at the cutting edge. The above distribution may be expressed as
n = max .( x ln )
m

where n = normal stress on the rake face at a distance x from the end of
contact length, and ln = natural contact length between tool and chip.

The total normal force on the rake face is given by

ln

Fn = b max ( x ln ) dx
m

0
b. max .ln
Fn =
(m + 1)

The distribution of shear stress consists of two zones. In zone 1, near the
cutting edge, the shear stress is constant and equal to K (= shear yield
stress of the deforming material). In zone 2, the shear stress is less than K
and proportional to normal stress n. In this zone, shear stress is given by
Coulombs law i.e.
= . n
The extent (l2) of slipping friction zone may be determined from the
condition m
l
. max . 2 = K
ln
which gives
1
K m
l2 = .ln
. max

The total tangential force may be determined by

Ft = Ft1 + Ft 2
Where Ft1 and Ft2 are the tangential forces in zone 1 and 2 respectively

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Ft1 = K .b(ln l2 )
l2 l2 m
x

0 0

Ft 2 = b. . n dx = b. . max dx
ln
The evaluation of the above integration gives
.b. max (l2 )m +1
Ft 2 = .
(m + 1) (ln )m
Now average coefficient of friction is given by
Ft (Ft1 + Ft 2 )
= tan = =
Fn Fn
After substituting the values of Ft1, Ft2 and Fn and further simplification, we
get
m +1
K .(ln l2 )(
. m + 1) + . max .(l2 )
= tan =
max .(ln )m +1

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