8/26/2015

What will I learn from this topic?

What is importance of forces in machining?

How are cutting forces estimated in machining?
Cutting Forces in Machining What are the factors influencing machining forces?
How forces help in optimizing machining performance?
Kaushal A Desai
Department of Mechanical Engineering
IIT Jodhpur

Why cutting forces are important in machining? Forces acting on Single Point Tool

Estimating power requirements and selection of power source Cutting force (T)
tangential to the job
Structural design of machine tool, cutting tool and work holding device
acts in the vertical plane
Evaluating the effect of process parameters downward for CCW rotation of
the job
Condition monitoring of cutting tools and machine tools
Feed force (Ff)
Machinability characteristics of work material parallel to the axis of the job
and in a direction opposite to
that of feed
acts in horizontal plane

Axial Force (R)

Perpendicular to the movement
cutting edge
Mutually perpendicular to T and
Ff

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Resultant Cutting Force Forces in 2D Cutting

Assumptions :
Tool is sharp, no rubbing between tool and workpiece
Deformation is two dimensional
Stress on the shear plane is uniformly distributed
Continuous type of chip without BUE
Chip come out of the shear zone at constant velocity
State of equilibrium

Forces acting on the Chip Merchants Circle: stepwise procedure

A Ff I

Fc

N E
T
Fs

F
G B

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Merchants Circle: stepwise procedure Merchants Circle: stepwise procedure

F = BG ; N = GA
A Ff I
A Ff I F = GJ + BJ

= AK + BJ
K
Fc H F = Ff cos + Tsin
Fc
D N = IJ - IK
N E N = T cos - Ff sin
Fs = BE , Fc= AE N E
T
= BH - EH T
= BH - ID
Fs
Fs = T cos - Ff sin Fs
F
G B F
Fc = AD + DE G B
= AD + IH J
Fc = Ff cos + Tsin

Velocity Relationships Work Done and Velocity Vector

A V Vs cos Vc sin
Vs sin
V = Velocity of tool relative to work, cutting velocity Vc
Vc = Velocity of chip relative to tool, chip flow velocity cos
Vs = Chip displacement veleocity along shear plane,
velocity of shear Vs V Vs cos Vs sin tan
V
DN
Cutting velocity, v
1000
Work done = F * V
C x

Vc In shearing = Fs * Vs
B
Against friction = F * Vc

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Merchants Constant Power Requirement in Machining

Of all the possible angles at which shear deformation can occur,

the work material selects a shear plane angle which minimizes V = Cutting velocity (between workpiece and tool edge)
energy and it is given by,
T = Cutting force
C 2
Elementary empirical relationships to note and remember:
To increase shear plane angle, Energy consumed in cutting per unit time: T x V N-m/min
Increase the rake angle Power consumed in cutting, P (watts): T x V/60
Reduce the friction angle (or co-efficient of friction) Metal removal rate, w (mm3/sec): 1000 f d V/60

Power required to remove the material per minute is a

measure of resistance to cutting; also indicates effectiveness
of cutting operation.

Power Requirement in Machining Specific Cutting Pressure

measure of resistance to cutting force offered by the material

T
Cutting force T
df *103 p N/mm2
Cut area df

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Specific Cutting Pressure Specific Cutting Pressure

Specific Cutting pressure depends on
Tool plan shape (depth of cut + rake angle + nose radius) An empirical relationship has been devised to represent such behavior
Feed rate
Cutting speed T C dx f y
C - constant for the material to be cut
x and y change as the shape of the cut area change
i.e x and y depend upon , tool nose radius and rake angle

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