Presentation

on

Metal Cutting

Doctoral Foundation Seminar

Presentation by:

Guided by:

Vijay Kumar Sharma

Dr. Anoop Kr. Singh

Roll no.:1610941106

Prof & Dy. Dean, CSME

Phd Scholar

Dr. KD Chattopadhyay
Prof. CSME

Chitkara School of Mechanical Engineering,

Chitkara University, Punjab

contents
1. Material Removal Processes
2. Types of cutting
3. Cutting Tool Classification
4. Single point cutting tool
5. Tool failure
6. Tool life
7. Chip formation
8. Thermal Aspects in Machining
9. Temperature and force measurements
10.Cutting fluids
11.Surface finish
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Material Removal Processes

A family of shaping operations, the common feature of which is removal of
material from a workpiece so the remaining part has the desired shape.
Simple 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

Metal Machining
Machining is an essential process of
finishing by which work pieces are
produced to the desired dimensions
and surface finish by gradually
removing the excess material from
the Workpiece in the form of chips
with the help of cutting tool. Cutting
action involves shear deformation of
work material to form a chip. As chip
is removed, a new surface is exposed.
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Why Machining is Important

1. Variety of work materials can be machined
Most frequently applied to metals

2. Variety of part shapes and special geometry features possible, such as:
Screw threads
Accurate round holes
Very straight edges and surfaces

3. Good dimensional accuracy and surface finish.

4. High productivity

Machining Operations
Most important
machining
operations:
Turning
Drilling
Milling
Other machining
operations:
Shaping and
planing
Broaching
Sawing
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Types of cutting
1. Orthogonal cutting process (Two - dimensional cutting) - The cutting edge or face of the
tool is 90 to the line of action or path of the tool or to the cutting velocity vector. This cutting
involves only two forces and this makes the analysis simpler.
2. Oblique cutting process (Three - dimensional cutting) - The cutting edge or face of the tool
is inclined at an angle less than 900 to the line of action or path of the tool or to the cutting
velocity vector. Its analysis is more difficult of its three dimensions.

Cutting Tool Classification

1. Single-Point Tools
One cutting edge
Turning uses single point tools
Point is usually rounded to form a nose radius

2. Multiple Cutting Edge Tools

More than one cutting edge
Motion relative to work usually achieved by rotating
Drilling and milling use rotating multiple cutting edge tools.

Geometry of single point cutting tool

Tool Geometry
Shank: The portion of the tool bit which is not ground to form cutting edges and is rectangular in cross section
Face: The surface against which the chip slides upward.
Flank: The surface which face the work piece. There are two flank surfaces in a single point cutting tool. One is
principal flank and the other is auxiliary flank.
Heel: The lowest portion of the side cutting edges
Nose radius: The conjunction of the side cutting edge and end cutting edge. It provides strengthening of the
tool nose and better surface finish.
Base: The underside of the shank.

Designation (Signature) of tool geometry in ASA System

Example: A tool having 7, 8, 6, 7, 5, 6, 0.1 as designation (Signature) in ASA
system will have
the following angles and nose radius.
Back rack angle = 7
Side rake angle = 8
Back clearance angle = 6
Side clearance angle = 7
(all angles are in degree)
End cutting edge angle = 5
Side cutting edge angle = 6
Nose radius = 0.1 inch

Tool Selection Process

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Elements of an Effective Tool

High Hardness
Resistance to Abrasion and Wear
Strength to resist bulk deformation
Adequate thermal properties
Consistent Tool life
Correct Geometry

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Tool failure
1. MECHANICAL DAMAGE
2. TOOL WEAR
Flank wear: finished part and flank of
tool
Crater Wear: chips and rake face of tool
Edge Wear: wear of drill tool at high
cutting speeds
Glazing: abrasive wheel become dull

Types of wear mechanism

Abrasive wear
Adhesion wear
Diffusion
Fatigue wear
Oxidation

Effects of tool wear

increased cutting forces
increased cutting
temperatures
poor surface finish
decreased accuracy of
finished part
May lead to tool breakage

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Tool life & Machinability

Useful life of a tool expressed in terms of time from start of a cut to termination point
(defined by failure criterion). Sometimes also expressed in terms of no. of the parts
machined.

Machinability
It is generally applied to the machining properties of work material.
It refers to material (work) response to machining.
It is the ability of the work material to be machined.
It indicates how easily and fast a material can be machined.

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Chip Formations
The form of the chips is directly or indirectly indicates:
Nature and behavior of the work material under machining condition.
Energy requirement in machining work.
Nature and degree of interaction at the chip-tool interfaces.

The form of machined chips depends mainly upon:

Work material.
Material and geometry of the cutting tool.
Levels of cutting velocity and feed and also to some extent on depth of cut.
Machining environment or cutting fluid that affects temperature and friction at the chip-tool and work-tool interfaces

Mechanism of chip formation

During this process three basic

types of chips are formed
namely:
Discontinuous
Continuous
Continuous with a Built-Up
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Edge (BUE)

Discontinuous Chips
Typically associated with brittle metals like Cast Iron
As tool contacts work, some compression takes place
As the chip starts up the chip-tool interference zone, increased
stress occurs until the metal reaches a saturation point and
fractures off the work piece.
Conditions which favor this type of chip
Brittle work material
Small rake angles on cutting tools
Coarse machining feeds
Low cutting speeds
Major disadvantagecould result in poor surface finish
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Continuous chips
Continuous ribbon of metal that flows up the chip/tool
zone.
Usually considered the ideal condition for efficient
cutting action.
Conditions which favor this type of
chip:

Ductile work
Fine feeds
Sharp cutting tools
Larger rake angles
High cutting speeds
Proper coolants

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Continuous with a Built-up Edge(BUE)

Same process as continuous, but as the metal begins to flow up the chip-tool
zone, small particles of the metal begin to adhere or weld themselves to the
edge of the cutting tool.
As the particles continue to weld to the tool it affects the cutting action of the tool.
This type of chip is common in softer non-ferrous metals and low carbon steels

Problems
Welded edges break off and can
become embedded in workpiece
Decreases tool life
Can result in poor surface finishes

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Thermal Aspects in Machining

Heat generated in cutting operation

Effects:
1. Tool
2. Workpiece
. Surface
. accuracy1.
T

Depends:
Rate of Cutting
Cutting conditions
Workpiece material

Distribution of Heat
heat generated in machining
operation =
chips+tool+workpiece+environment
Q = Q1 + Q2 + Q3 + Q4
Q1=heat taken away by the chips
Q2=heat conducted in to tool
Q3=heat conducted in to workpiece
Q4=heat dissipated in environment

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Cutting Temperature measurements

1. Toolchip thermocouple method
Using this method, K. Trigger
determined the speedtemperature
relationship to be of the form:
T = K vm
where T = measured toolchip interface
temperature

2. Photo cell technique: cell

receive radiations
3. Infrared photographic
technique

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Cutting force measurements

Force measurements is
done
Clearly understanding the
process of metal cutting
Investigation of tool wear and
tool life
Designing of cutting tools
Investigation of machinability
problem
Determining power requirements
Designing of jigs and fixtures

Device used for measurements of

force is Tool Dynamometers. Various
types are:
Mechanical dynamometers..with
calibrated dial indicators shows
force readings
Strain
gauge
dynamometers.resistance
diff.
shows reading in galvanometer,
Wheatstone bridge.
Hydraulic
and
pneumatic
dynamometers.pressure gauges
are used
Electric
dynamometers....use
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transducers

CUTTING FLUIDS
Purpose of using cutting fluids

Absorb and carry away the heat

Cool the workpiece and tool.
Reduce the friction
Wash away the chips.
Carry away the built-up edges
Formed.
Give very fine surface finish
Prevent corrosion

Types of cutting fluids

Solid or semi-solid lubricant: Paste,
waxes, soaps, graphite, etc.
Water
Soluble oil
Cutting oils: mineral oils with
vegetable, animal or marine
oils
Chemical fluids: organic and
inorganic

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SURFACE FINISH

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thanks

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