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Chapter-20
TOPICS
Introduction
Temperature in cutting
Machinability
Fundamentals of cutting
Fig 20.1 Examples of cutting process Fig 20.3 Schematic illustration of a two-
dimensional cutting process,also called
orthogonal cutting.Note that the tool shape
and its angles,depth of cut,to,and the cutting
speed are all independent variables.
Fig 20.4 (a) Schematic illustration of the basic mechanism of chip formation in metal
cutting. (b) Velocity diagram in the cutting zone.
Mechanism of chip formation
Chip compression ratio = 1 / r
Always > unity
On the basis of fig 20.4-a
Shear strain gama
Gama = AB/OC = AO/OC + OB/OC
Gama = Cot Pi + tan ( Pi Alpha )
Note : for actual cutting operation shear
strain > 5
Mechanism of chip formation
Shear angle adjusts itself to minimize
cutting force
Shear plane is the plane of maximum shear
stress
Pi = 45 + Alpha / 2 Beta / 2
Beta : Friction angle
Mu coefficient of friction
Mu = tan beta
Mechanism of chip formation
Mass continuity has to be maintained
So , we have
V To = Vc Tc
Vc = Vr
Vc = V Sin pi / Cos ( pi Alpha )
Vc : Velocity of a chip
V : Cutting Speed
Vs : Velocity of shearing
From trigonometric relation
V / cos ( pi Alpha ) = Vs / Cos ( Alpha ) = Vc /
Sin ( pi )
Types of chips
Continuous
Built up edge
Serrated or segmented
Discontinuous
Fig20.5 Basic types of chips and their photomicrographs produced in metal cutting (a) continuous ship
with a narrow,straight primary shear zone; (b) secondary shear zone at the chip tool interface;(c)
continuous chip with large primary shear zone; (d) continuous chip with built-up-edge;(e)
segmented or nonhomogeneous chip and (f) discontinuous chips
Continuous chips
Fig:Various chips produced in turning: a)tightly curled chip b)chip hits workpiece
and breaks c)continuous chip moving away from workpiece;and d)chip hits tool
shank and breaks off
Chip Formation in Nonmetallic Materials
Fig: a) cutting with an oblique tool b) Top view showing the inclination angle, i.
c) Types of chips produced with different inclination
Mechanism of Oblique Cutting
The cutting edge is at an angle i, called inclination angle.
The chip movement is in lateral direction
Fig: a)right hand cutting tool.Although these tools have traditionally been produced
from solids tool-steel bars,they have been largely replaced by carbide or other inserts
of various shapes and sizes,as shownin b).The vcarious angles on these tools and
their effects on machining are described
Temperature In Cutting
Fig (a) Schematic illustrations of types of wear observed on various types of cutting tools .(b)
Schematic illustrations of catastrophic tool failures.A study of the types and mechanism of
tool wear and failure is essential to the development of better tool materials
Forces acting in 2-Dimensional cutting
Cutting forces can be
measured by using suitable
dynamometers or force
transducers mounted on the
machine tool
They can also be calculated
from the amount of power
consumption,that occurs
during cutting.
Fig :Forces acting on a cutting tool in a two
dimensional cutting .Note that the resultant
force,R,must be collinear to balance the
forces
THE END