Manufacturing

Engineering I (MEng
3141)

Lecture on
Cutting force

6/4/17 Cutting force By Mesay Alemu,Jimma,Ethiopia 1

 Cutting force
2

General method of cutting force

measured.
Analytical and Experimental
Using Numerical (calculation)
Easy quick and inexpensive, very

approximate, average and Unable to

reveal dynamic aspect
Dynamometers device(cutting force

Dynamometers)
Accurate , can depict both static and
Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17
 Cutting force components and their
significances
3

Cutting force R resolved into PX, PY andTurning

PZ force resolved into PZ, PX and PY

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17

 Significance of PZ, PX and PY
4

PZ : called the main or major component as it is

the largest in magnitude. It is also called power
component as it being acting along and being
multiplied by VC decides cutting power (PZ.VC)
consumption.
Py : may not be that large in magnitude but is
responsible for causing dimensional inaccuracy
and vibration.
PX : It, even if larger than PY, is least harmful and
hence least significant.

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17

 The cutting force
tool video\dislocation density simulation
5
in cutting of titanium using Abaqus.avi - Y
xternally applied forces tool video\Orthogonal Cutting_ ALE A
ouTube.FLV
P

Fc

Fc Cutting force, Ft Thrust force Ft

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17

 The cutting force
6

Forces on the tool

Fn

F Friction force, Fn Normal force

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17

 The cutting force
7

Forces on the chip

Fs

Fco

Fs Shear force, Fco Compressive force

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17

 The cutting force
8

Merchants theory

1

4 2

Fs

Fco -
Ft
R
F
- F
c
friction angle
Fn
Merchants Circle
Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17
 Cutting force cont.
9

R Fc Ft
2 2
1
2

R F f Fn
2 2
1
2

R F 1
2 2
Fco
2
s

The shear force FTos shear a work material can be expressed in terms of
cutting force Fc
Fs Fc cos Ft sin

Area of shear As is given by

Ac
As
Cuttingsin By Mesay Alemu,Jimma,Ethiopia
force 6/4/17
 The cutting force cont.
he shear strength of a material s on the shear plane
ay be obtained by
10

Fs ( F cos Ft sin ) sin

s c
As Ac

Ernest and merchant theory suggests that is
formed in such a way that the energy required to
shear a material wil Fs

Shear strength
Fco s

R As Area of shear

ACArea of uncut chip

Fs FR cos( )
s Ac
Fs Cutting
s As
force By Mesay Alemu,Jimma,Ethiopia 6/4/17
sin
 The cutting force cont.

11

s Ac 1
FR cos
sin

FC FR cos( )

s Ac cos
Fc cos
sin
The equation my now be differentiated with
respect to
equal to zero to findF cthe value of
for which is
dFminimum.
c
0
d

Solution 4 1 2
Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17
 The cutting force cont.

12

he result didnt agree with the experimental , since the assum

dnt considered the dependency of shear stress with shear a
erchant reconsidered the assumption and he included his ne
ssumption

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17

 The cutting force cont.
13

Fco FR sin( )
Fs
s Ac
Fco s As
sin
sin Fco
s ( FR sin( ))
Ac R
s
cot( )
s
s s cot( )

s
s so k
cot( )
so
s
tan(By Mesay
1 kforce
Cutting )
Alemu,Jimma,Ethiopia 6/4/17
 The cutting force cont.

14

s f ( , , )
The new equation for Fc
Ac so cos( )
FC
sin cos( )(1 k tan( ))

t is now assumed that K and so are constants for a particular

Material
Ac and are constants for the cutting operation
dFc
0
d

1
2 c c Is constant
Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17
 Lee and Shafers solution
15

The theory of lee and Shafer's was the

result of an attempt to apply the
plasticity and slip lines theory to
orthogonal metal cutting
Assumptions
The material is rigid
The behavior of the material is independent of
the rate of deformation
The effect of temperature during deformation is
neglected

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17

 Lee and Shafers solution
16

ABC is deformation zone

AB shear plane
AC is stress free so that
slip lines
meet this line at an angle
of 45
Slip lines :
Parallel to AB
to
Perpendicular
4 AB

The theory of lee and Shafer's is not applied for

tools with negative rake angle .
Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17
 Influence of cutting parameters on cutting
force
17

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17

 Friction force
18

Fig Sliding friction Fig Sticking friction

Ar Aa Apparent area
Real area
Fn
Ar F f f Ar
y f Shear strength

Ff Ff Friction force

Fn Fn Normal force

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17

 Cutting forces on turning
19

Fc Cutting force
Ff Feed force
Thrust force

No motion on the radial

No work done by radial
motion
The feed force is negligible
Power(P) needed for turning
is : P
FcVc Watt
60
Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17
 Specific cutting Energy
20

The rate of energy consumption during Pm

machining is
Pm FcV
The energy consumed per unit volume of
Ps cutting energy
metal removed ,specific
is Pm Fc
Ps
Zw Ac
Pm Power consumed
Fc
Cutting force
Ps Specific cutting energy
Z w Metal removal rate
Ac Un deformed chip cross
section
Cutting force By Mesay Alemu,Jimma,Ethiopia 6/4/17