Fundamentals of Cutting: Chapter-20
Fundamentals of Cutting: Chapter-20
Fundamentals of Cutting: Chapter-20
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