Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Sh
ea a2 P
2
rp
lan
e v
1
a1
workpiece
14
4.2.2 Coefficient of chip upsetting (k): n
If: a …… chip thickness before chip formation. s
b …… chip width a
b
Then theoretical cross-section area of chip is:
Ft a b s t
Feed
but actual area will be different due to deformation.
L
Considering equal volume (V1 = V2):
where
b
V1 and V2 are volume of chip before and after cutting.
a1 L1 b1 a 2 L 2 b2
a
Chip segment
If: b1 = b2
Then a1 L1 a 2 L2
a 2 L1
k 1
a1 L2
where k is the coefficient of chip upsetting. When deformation a2 K
The values of a1 and L1 can be obtained before cutting while a2 and L2 are measured.
Example: A cylindrical workpiece with a longitudinal slot is used as shown in the figure
where L1 can be calculated as follows:
L1 D t b
n
D
L1
Then K
b
L2
t
1 K
HB HB
15
2- Cutting conditions:
K
1
v v
(v deformation a2 1 K )
1
K
s , t s , t
(s , t deformation a2 1 K )
3- Tool geometry
K
1
( (+) P deformation a2 1 K)
1
30 60 90
16
4- Coefficient of friction (on tool face)
1 K
with cooling
( deformation a2 1 K )
4.4 Types of chip
1. Continuous chip: It appears when machining ductile and soft
materials such as Aluminum and low carbon steel and at v ,
s , .
2. Sectional chip: It appears when machining hard and ductile
materials such as high carbon steel and at v, s , .
3. Broken chip: It appears when machining hard and brittle materials such as cast iron
and hard bronze and at v, t , .
4. For the best surface quality, it is recommended to have sectional chip.
4.5 Types of cutting
17
4.6 Phenomena accompanying chip formation
4.6.1 Built-up-edge (B.U.E) formation
B.U.E consists of highly strained material
adhering to the tool tip. The normal
pressures between the chip and the tool are
a
very high (1000 – 2000 Mpa) and the
p
Chi
temperatures at the contact are high (600 -
1000C) depending mainly on the cutting B.U.E workpiece
speed. Under these conditions, a layer of
the chip material adheres to the tool.
Characteristics of B.U.E
Formed from the workpiece Unstable and not uniform in size.
High deformation High hardness.
Non uniform microstructure
Elastic deformation
(-) on subsurface layer
d
Core
subsurface layer
d
19 Core
and contracts causing a tensile stress on subsurface layer.
The residual stresses effect:
1. Constrain atoms mobility
2. tensile stress decreases fatigue life
3. compressive stress increases fatigue life
4.6.2.3 Surface texture
Ra = Ridle + Rnatural
Where:
Ridle is due to tool geometry and feed (s) (tool marks).
Rnatural is due to vibration, B.U.E formation, tool wear and variation of cutting force and
cutting temperature.
Ridle = Rmax th
Calculation of Rmax th
a) When r 0
r Rmax th
s2 s/2
r2
2
4
s2
r 2 2rRmax th Rmax th
4
2
r
Tool
Rmaxth2 0 (very small value). Then
s2
Rmax th
8r
b) when r = 0
s x1 x2
cot
x1 `
Rmax th
maxth
x2
cot
R
Rmax th
cot cot
x1 x2
s x 1 x 2
r=0
Rmax th Rmax th
then
s
Rmax th
cot cot
20