THEORY OF METAL CUTTING

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1 THEORY OF METAL CUTTING

2 INTRODUCTION Overview of Machining Technology Mechanism of chip formation Orthogonal and Oblique cutting Single Point and Multipoint Cutting Tools Machining forces - Merchant s Circle Diagram Thermal aspects of metal machining Cutting fluids Machinability - Cutting tool materials Tool wear and Tool life calculations.

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

4 Machining Operations Most important machining operations: Turning Drilling Milling Shaping and planning Broaching Sawing Machining Operations

5 Turning Drilling Milling

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7 Mechanism of chip formation Metal ahead of the cutting tool is compressed and this results in the deformation or elongation of the crystal structure resulting in a shearing of the metal. As the process continues, the metal above the cutting edge is forced along the chip-tool interference zone and is moved away form the work. Cutting action involves shear deformation of work material to form a chip. As chip is removed, a new surface is exposed

8 Showing shear zone rather than shear plane. Also shown is the secondary shear zone resulting from tool-chip friction

9 Types of chips Continuous chip Discontinuous chip Continuous chip with Built-up Edge (BUE)

10 Continuous Chip Ductile work materials (e.g., low carbon steel) High cutting speeds Small feeds and depths Sharp cutting edge on the tool Low tool-chip friction

11 Discontinuous Chip Brittle work materials (e.g., cast irons) Low cutting speeds Large feed and depth of cut High tool-chip friction

12 Continuous with BUE Ductile materials Low-to-medium cutting speeds Tool-chip friction causes portions of chip to adhere to rake face BUE formation is cyclical; it forms, then breaks off

13 Forces Acting on Chip Friction force F and Normal force to friction N Shear force F s and Normal force to shear F n Forces acting on the chip in orthogonal cutting

14 Coefficient of Friction Coefficient of friction between tool and chip: F N tan Shear Stress Shear stress acting along the shear plane: S F A s s A s tow sin where A s = area of the shear plane

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16 Orthogonal and oblique cutting Orthogonal Cutting (2-D Cutting): Cutting edge is straight, parallel to the original plane surface at the workpiece and perpendicular to the direction of cutting. E.g. Operations: Lathe cut-off tools Straight milling cutters etc. Oblique Cutting: Cutting edge of the tool is inclined to the line normal to the cutting direction. In actual machining, Turning, Milling etc cutting operations are oblique cutting.

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

20 (a) A single-point tool showing rake face, flank, and tool point (b) helical milling cutter, representative of tools with multiple cutting edges

21 TOOL ELEMENTS

22 TOOL ANGLES

23 TOOL SIGNATURE

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25 Forces of a Single Point Tool Cutting Conditions in Machining The three dimensions of a machining process: Cutting speed v primary motion Feed f secondary motion Depth of cut d penetration of tool below original work surface For certain operations, material removal rate can be found as MRR = v f d where v = cutting speed; f = feed; d = depth of cut

26 Cutting Conditions for Turning Figure Cutting speed, feed, and depth of cut for a turning operation

27 The work material offers a resistance to the cutting tool during metal cutting. This is overcome by the cutting force applied to the tool face. The magnitude of cutting force depends upon following factor : Material Rate of feed Depth of cut Tool angle Cutting speed Coolant

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34 Stress and strain on the chip

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