Metal Cutting

Machining Technology
Material Removal Rate
Orthogonal Cutting
Chip Formation
Forces in Metal Cutting
Merchant Equation
Turning vs. Orthogonal
Power and Energy Relationships
Cutting Temperature

IE210 Production Engineering

Metal Cutting

Machining Technology

IE210 Production Engineering

Metal Cutting

Machining Technology
Turning

Peripheral
Milling

IE210 Production Engineering

Metal Cutting

Drilling

Face Milling

Other Processes
Shaping, Planing, Grinding, Broaching, etc.

Material Removal Rate

MRR vfd
Roughing(R)
f 0.4 1.25mm / rev
d 2.5 20mm
Finishing(F)
f 0.125 0.4mm / rev
d 0.75 2.0mm
v R v F

IE210 Production Engineering

Metal Cutting

Orthogonal Cutting
r

to
ls sin

tc ls cos( )

tan

IE210 Production Engineering

Metal Cutting

r cos
1 r sin

AC AD DC

tan( ) cot
BD
BD

Chip Formation

Brittle Materials
Ductile Materials
Low Cutting Speeds High Cutting Speeds
High Friction
Low Friction
Large Feed and Depth Low Feed and Depth

IE210 Production Engineering

Metal Cutting

Ductile Materials
Low Cutting Speeds
High Friction

Forces in Metal Cutting

(1)
(2)
(3)
(4)

Friction Force (F)

Normal Force to Friction (N)
Shear Force (Fs)
Normal Force to Shear (Fn)

F
N

tan

Fs
As

As
IE210 Production Engineering
Metal Cutting

to w
sin

Forces in Metal Cutting

Using Dynamometer we can determi

(5) Cutting Force (Fc)
(6) Thrust Force (Ft)

F F c sin Ft cos
N Fc cos Ft sin
Fs Fc cos Ft sin
Fn Fc sin Ft cos

IE210 Production Engineering

Metal Cutting

Merchant Equation
Merchant states that the shear angle predominates.
For all other angles shear stress is less than shear strength.
Shear angle is that which minimises energy.

Fc cos Ft sin

to w / sin
d
0
d

45
2 2

IE210 Production Engineering

Metal Cutting

Power & Energy

Relationships
P Fc v
U

IE210 Production Engineering

Metal Cutting

P
Fv
F
c c
MRR vto w to w

Cutting Temperature

U vto 0.333
T 0.4
C K

Temperature measurement usually uses a tool-chip thermocouple

IE210 Production Engineering

Metal Cutting