M14ME2005

MACHINING PROCESS
Unit 1

Lecture By: GPR, KSMS

Objective

Chip
Chip Types
Types

Formation
Formation Mechanism
Mechanism

Orthogonal
Orthogonal cutting
cutting

Merchant
Merchant and
and Lee
Lee and
and Shaffer
Shaffer theory
theory

Cutting
Cutting force
force

Temperature
Temperature in
in metal
metal cutting
cutting

Tool
Tool life
life and
and tool
tool wear
wear

Cutting
Cutting tool
tool materials
materials

cutting
cutting fluids
fluids

Machining
Machining types
types
Turning
Turning
Drilling
Drilling
Milling
Milling
Shaping
Shaping
Planing
Planing
Broaching
Broaching

Machining tools
Single
Single point
point

Multiple
Multiple point
point

Machining tool materials

Most
Most modern
modern cutting
cutting tool
tool materials
materials are
are aa matrix
matrix of
of
materials
materials designed
designed to
to be
be very
very hard.
hard.

Machining surface finish

Machining terminology
Speed
Speed surface
surface cutting
cutting speed
speed (v)
(v)
Feed
Feed advance
advance of
of tool
tool through
through the
the part
part (f)
(f)
Depth
Depth of
of cut
cut depth
depth of
of tool
tool into
into part
part (d)
(d)
Rake
Rake face
face tools
tools leading
leading edge
edge
Rake
Rake angle
angle slant
slant angle
angle of
of tools
tools
leading
leading edge
edge ()
()

Flank
Flank following
following edge
edge of
of cutting
cutting tool
tool
Relief
Relief angle
angle angle
angle of
of tools
tools following
following edge
edge above
above part
part surface
surface

Machining terminology (cont.)

ls

Chip thickness thickness

thickness of machined
machined chip
chip (t
(tcc ))
Depth of cut = too

Orthogonal model

Shear plane length measured

measured along
along shear
shear plane
plane chip
chip (l
(lss ))
Chip width (not shown) width
width of
of machined
machined chip
chip (w
(w ))
Shear angle angle
angle of shearing surface measured from
from tool direction
direction ()
()

Cutting conditions
Note: - Primary cutting due to speed
- Lateral motion of tool is feed
- Tool penetration is depth of cut
The three together form the material removal rate (MRR): MRR = v f d
with units of (mm/min)(mm/rev)(mm) = mm33/min/rev (or vol/min-rev)
Types of cuts:
Roughing:

feeds of 0.381 1.270 mm/rev,

depths of 2.540 19.050 mm

Finishing:

feeds of 0.127 0.381 mm/rev,

depths of 0.762 1.905 mm

Cutting geometry
Chip thickness ratio = r = to / tc
From the shear plane geometry:
r = ls sin/[ls cos(-)]
which can be arranged to get
tan = r cos /[1 r sin]

Obviously, the assumed failure

mode is shearing of the work along
the shear plane.

Cutting geometry
Note from the triangles in (c) that the shear strain () can be estimated as
= AC/BD = (DC + AD)/BD = tan(- ) + cot
Thus, if know r and
can determine , and
given and , can
determine .

Cutting forces
Since R = R = R, we can get the force balance
equations:
F = Fc sin + Ft cos

F = friction force; N = normal to chip force

N = Fc cos - Ft sin

Fc = cutting force; Ft = thrust force

Fs = Fc cos - Ft sin
force
Fn = Fc sin + Ft cos

Fs = shear force; Fn = normal to shear plane

Friction angle =
tan= = F/N
Shear plane stress:
= Fs/As
where
As = to w/sin

Forces are presented as

function of Fc and Ft because
these can be measured.

Cutting forces given shear strength

Letting S = shear strength, we can derive the following equations for the
cutting and thrust forces*:
Fs = S As
Fc = Fs cos (cos (
Ft = Fs sin (cos (
* The other forces can be determined from the equations on the previous slide.

Merchant equations
Combining the equations from the previous slides:
= (Fc cos - Ft sin tow/sin

Merchant eqn

The most likely shear angle will minimize the energy.

The Merchant eqn is a function of
Applying d/d = 0 gives:
= 45 +

Merchant reln

What does the Merchant relation indicate?

- increase in friction angle decreases shear angle
- increase in rake angle increases shear angle

and . Where did these variables

come from?

Answer - Although the Merchant

eqn is not shown as a direct function
of and , these enter from the
equations for Fc and Ft from the
previous slide!
If we increase the shear angle, we
decrease the tool force and power
requirements!

Cutting models
The orthogonal model for turning approximates the complex
shearing process:

to = feed (f)
w = depth of cut (d)

Cutting power
Power is force times speed:
P = Fc v (ft-lb/min)
The cutting horsepower is
hpc = Fc v/33,000 (hp)
The unit horsepower is
hpu = hpc/MRR

units?

Due to efficiency losses (E about 90%), the gross

hp is
hpg = hpc/E

Cutting energy

Specific energy is

U = Fc v/(v tow) = Fc /(tow) (in-lb/in3)

The table shown contains power and specific energy ratings for several work materials at a chip thickness
of 0.01 in. For other chip thicknesses, apply the figure to get a correction factor multiply U by correction
factor for thickness different than 0.01).

Machining example
In orthogonal machining the tool has rake angle 10, chip thickness before cut is to = 0.02
in, and chip thickness after cut is tc = 0.045 in. The cutting and thrust forces are measured
at Fc = 350 lb and Ft = 285 lb while at a cutting speed of 200 ft/min. Determine the
machining shear strain, shear stress, and cutting horsepower.
Solution (shear strain):
Determine r = 0.02/0.045 = 0.444
Determine shear plane angle from tan = r cos /[1 r sin]
tan = 0.444 cos /[1 0.444 sin] => = 25.4
Now calculate shear strain from = tan(-) + cot
= tan(25.4 - 10) + cot 25.4 = 2.386 in/in

answer!

Machining example (cont.)

In orthogonal machining the tool has rake angle 10, chip thickness before cut is to = 0.02
in, and chip thickness after cut is tc = 0.045 in. The cutting and thrust forces are
measured at Fc = 350 lb and Ft = 285 lb while at a cutting speed of 200 ft/min. Determine
the machining shear strain, shear stress, and cutting horsepower.
Solution (shear stress):
Determine shear force from Fs = Fc cos - Ft sin
Fs = 350 cos 25.4 - 285 sin 25.4 = 194 lb
Determine shear plane area from As = to w/sin
As = (0.02) (0.125)/sin= 0.00583 in2
The shear stress is

= 194/0.00583 = 33,276 lb/in2 answer!

Machining example (cont.)

In orthogonal machining the tool has rake angle 10, chip thickness before cut is to =
0.02 in, and chip thickness after cut is tc = 0.045 in. The cutting and thrust forces are
measured at Fc = 350 lb and Ft = 285 lb while at a cutting speed of 200 ft/min. Determine
the machining shear strain, shear stress, and cutting horsepower.

Solution (cutting horsepower):

Determine cutting hp from hpc = Fc v/33,000
hpc = (350) (200)/33,000 = 2.12 hp answer!

Cutting temperatures
In machining 98% of the cutting energy is converted into
heat. This
energy flows into the work part, chip, and tool. Cook
determined an experimental equation for predicting the
temperature rise at the
tool-chip interface during machining:
T = 0.4 U (v to/K)0.333/( c)
where

Example in text calculates T = 936 total tool

temperature, given v = 200 ft/min, c = 120 inlb/(in3- F) and K = 0.125 in2/s

T = mean temperature rise (F)

U = specific energy (in-lb/in3)
v = cutting speed (in/s)
to = chip thickness before cut (in)
c= volumetric specific heat of the work material (in-lb/
(in3-F)) K = thermal diffusivity of the work material (in2/s)

Cutters

Toroid

Cutters