Manufacturing Technology MEC205

Metal Machining

Tool Geometry

SIDE RELIEF
SIDE CLEARANCE

CHIP F0RMATION
The metal in front of the tool rake face gets immediately compressed first elastically and then plastically. The actual separation of the metal starts as a yielding or fracture, depending upon the cutting conditions, starting from the cutting tool tip. The chip after sliding over the tool rake face would be lifted away from the tool, and the resultant curvature of the chip is termed as chip curl.

TYPES OF CHIPS
Discontinuous chip Continuous chip, and Continuous chip with BUE Serrated Chip

Continuous Chip Continuous chips are normally produced when machining steel or ductile metals at high cutting speeds. Continuous chip is possible because of the ductility of metal flows along the shear plane instead of rupture. Sharp cutting edge, small chip thickness (fine feed), large rake angle, high cutting speed, ductile work materials and less friction between chip tool interface through efficient lubrication

Continuous Chip with BUE When the friction between tool and chip is high while machining ductile materials, some particles of chip adhere to the tool rake face near the tool tip. When such sizeable material piles up on the rake face, it is termed as built up edge (BUE). As the size of BUE grows larger, it becomes unstable and parts of it gets removed while cutting. The removed portions of BUE partly adheres to the chip underside and partly to the machined surface

Continous chip with build up edge

Discontinuous Chip When brittle materials like cast iron are cut, the deformed material gets fractured very easily and thus the chip produced is in the form of discontinuous segments. Cutting force becomes unstable with the variation coinciding with the fracturing cycle. Higher depths of cut (large chip thickness), low cutting speeds and small rake angles are likely to produce discontinuous chips.

Serrated Chips
Semicontinuous - saw-tooth appearance Cyclical chip forms with alternating high shear strain then low shear strain Associated with difficult-to-machine metals at high cutting speeds

THIN AND THICK SHEAR MODEL

Orthogonal Cutting
Oblique cutting is more practical while orthogonal cutting is convenient for analysis.

Mechanics of Orthogonal Cutting

The current analysis is based on Merchant's thin shear plane model considering the minimum energy principle. This model would be applicable at very high cutting speeds, which are generally practised in production

Assumptions
The tool is perfectly sharp and no contact along the clearance face. The surface where shear is occurring is a plane. The cutting edge is a straight line extending perpendicular to the direction of motion and generates a plane surface as the work moves past it. The chip does not flow to either side or no side spread. Uncut chip thickness is constant. Width of the tool is greater than the width of the work. A continuous chip is produced without any BUE. Work moves with a uniform velocity. The stresses on the shear plane are uniformly distributed

Forces and Mechanics of Cutting

Why should we know?
Power requirement for the machine tool can be calculated Design of stiffness, etc. for the machine tolerances Whether workpiece can withstand the cutting force

Merchant's Analysis
Fv-Force perpendicular to the primary tool motion (thrust force) Fs-Force along the shear plane Ns-Force normal to the shear plane F -Frictional force along the rake face N -Normal force perpendicular to the rake face R = R'

Note :- in case of cos it will be cos in formulae of Ns

Putting the value of Ns in this both equations

Minimum energy condition

 Cutting Force FC depends on

FC increases as t0 increases FC decreases as rake angle increases and as speed increases

Why FC is affected by speed:

As speed goes up, shear angle goes up, and friction reduces.

Forces can also be affected by the nose radius. Large nose radius increases force. (Blunt tool)