MECH

Chip Formation Mechanics Power, Energy, Forces, Temperature
ver. 1
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2009
Overview
Chip formation mechanics
Power Energy Forces Torques q Temperature Oblique cutting
Idealized Chip Chip-formation formation Process

chip shear zone cutting tool
workpiece
Chip-formation p Geometry y
primary shear zone
chip
B to workpiece
tc A
tool V (cutting velocity)
Cutting Energy, Power, Forces & Torques

To get forces and torques, calculate p power ( (energy), gy), and back calculate P=Fxs P=Tx
Specific Cutting Energy (u)

energy (work) to form chip u= volume of chip Energy Work = u= V l Volume V l Volume
Cutting Work (W)

Work (W) done by cutting force (F) = cutting power (P) x cutting time (t) W=Pt
Work Power = Volume Volume time
Volume = MRR time
Cutting Power (P)

E W P =u= = V V MRR
or P = u x MRR
Cutting g Power ( (P) )

So, we can calculate P = u x MRR Hence, the force or torque from: P=Fxs P=Tx
u is composed p of:
us, the shear energy per unit volume uf, frictional energy per unit volume chip curl energy chip acceleration kinetic energy surface energy of new surfaces
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2009 10
Where does cutting energy go?

90% to chip 5% to tool 5% to workpiece
11
u can be obtained in two ways Tabulated Estimated

u ~ HB
12
Cutting Energy (u)

As a first approximation:
u us + uf us 0.75 0 75 - 0.8 08u

hence
u 1.5 us
13
Estimation of u
Assume a simple, rigid-perfectly plastic material:
u s = d = o = fm
HB for heavily cold-worked metals o 3 1 2 2 4
14
Estimation of u
o 1 HB 2 6
fm
1 2 u s HB HB 3 3
15
What number to use?

From above
u 1.5 us us (1/3 to 2/3) HB u (1/2 to 1) HB so, if no data, u HB

Comparison of Tensile and Cutting (Ex. 1-1)

304 stainless steel rod do = 0 0.5 5 in in, df = 0.48 0 48 in in, lo = 6 in Wh What t is i th the energy required i d using i tension? What is the energy required using cutting?
Tension: Ex Ex. 1 1-2 2
n +1 K 1 d1 = u = n +1
1
u volume = Energy
K = 185,000 psi; n = 0.45
Tension - Ex. Ex 1-3 13

n +1 K 1 Energy = Aolo n +1
1 = 2 ln
0 .5 = 0.0816 0.48
( 185,000 ) (0.0816 )1.45 2 = (0.25) (6)

1.45 = 3,970 in lbf = 449 J
19
Cutting g - Ex. 1-4

Energy = (specific cutting energy) * (volume removed)
E = u
uss 1.5 hp min/in3 x 550 x 60 x 12 = 594,000 594 000 in in-lbf/in lbf/in3

E = 594,000
( D 4
2 i
D2 f ) l
( 0.5 4
0.482 ) 6
= 54,650 in-lbf (6,176 J)

Comparison - Ex. Ex 1-5 15

Tension: E = 3,940 in-lbf (449 J) Cutting: E = 54,650 in-lbf (6,176 J)
21
Turning vs vs. Orthogonal Cutting

Terminology used in a turning operation on a lathe, where f is the feed rate (in./rev or mm/rev) and d is the depth of cut. In turning, turning the orthogonality orthogonality is to the left in the drawing, hence a change of coordinate system is needed. If you were doing a diametral cut-off (p (plunge g cut) ) operation, no change would be needed. Note that feed in turning is equivalent to the depth of cut in orthogonal th l cutting, tti and d th the depth of cut in turning is equivalent to the width of cut in orthogonal cutting.
22
Relation between u and t0

As the depth p of cut decreases, , the surface area to volume ratio increases, hence friction ( (energy) gy) increases Since
u us + u f
Hence
1 u t0
Turning Power and Force Force- Ex. Ex 2-1 21

Turning Titanium: speed = 1 m/s = 200 sfpm feed f d rate t = 0.1 0 1 mm/rev / =0 0.0004 0004 / rev depth of cut = 3 mm = 0.1 What is cutting power and cutting force?
24
Power - Ex. 2 2-2 2

u 0.06 kW/cm3/min = 3.6 W/mm3/sec MRR =Q = sfd = 1 1,000 000 x 0 0.1 1x3 = 300 mm3/sec P = u x MRR = 3 3.6 6 x 300 = 1,080 ,080 W = 1.45 hp
Force - Ex. Ex 2-3 23

F = P/s = 1,080 W 1 m/s = 1,080 1 080 N (243 lbf)
26
u vs vs. t0 in Turning Ex. Ex 3-1 31

If And
s = 1 m/s / f (depth of cut) = 0.01, 0.02, 0.05, 0.1 mm/rev d (width of cut) = 3 mm
u 2.2
1
0.4 t0
(W s / mm )
3

Fixed speed (1 m/s), width of cut (3 mm)
feed rate u (mm/s) (W-s/mm3) 0.01 0 02 0.02 0.05 0.1 13.9 10 6 10.6 7.3 5.5 MRR (mm3/s) 30 60 150 300 Power (W) 416 631 1094 1658
1800 1600 1400 1200 1000 800 600 400 200 0 0 P Power (W) MRR (mm3/s)
0.02
0.04
0.06
0.08
0.1
feed rate (mm/s)
28

For a constant power = 1700 W, width of cut = 3 mm feed rate u (mm/s) (W-s/mm3) 0.01 13.9 0 02 0.02 10 5 10.5 0.05 7.3 01 0.1 55 5.5 Speed (mm/s) 4082 2693 1554 1025 MRR (mm3/s) 122 162 233 308
29
Force Ex. Ex 4-1 41

Drilling a hole into aluminum
hole diameter = 1 inch feed rate = 5 in/min speed = 200 rpm
Determine power, torque, force on drill bit, force on operator u = 0.18 hp/in3/min
Force Ex. 4-2

MRR different than turning
here, drill speed p only y matters for determining g feed rate and rotational speed MRR = Q = VA = feed rate x cross sectional area
4 4 Power = u MRR = 0.18 3.93 = 0.71 hp
MRR = f
= 5
(1)
= 3.93 in 3 / min
ft lbf sec 0.71 hp h 550 60 power sec hp min Torque = = 18.6 ft lbf = rev rad 200 2 min i rev
Force Ex. Ex 4-3 43

F Force on drill d ill bit
Force =
Torque 18.6 ft lbf = 446.4lbf = drill bit radius 0.5in 1 ft 12in
32
Force Ex. Ex 4-4 44

Force on operator p
Torque 18.6 ft lbf = Force = = 37.2lbf ft 1 distance to application point 6in 12in
6 in
33
Force Ex. Ex 5-1 51

Slab milling titanium
speed of mill (V) = 500 rpm mill diameter (D) = 3 in mill width = 4 in work piece width = 4 in speed d of f work k piece i [f [feed d rate] t ] (v) ( ) = 5 in/min i / i depth of cut (d) = 0.2 in u=1 1.2 2 hp/in3/min
Determine power, torque, and force

Force Ex. Ex 5-2 52

MRR is different from turning. g
Here, speed of mill only matters to determine feed rate and rotational velocity. MRR = Q = velocity x cross-sectional area
MRR = d b v = 0.2 4 5 = 4 in / min

Power = u MRR = 1.2 4 = 4.8 hp
35
Force Ex. Ex 5-3 53

sec ft lbf 4.8 hp 550 60 power sec hp min = Torque = = 50.4 ft lbf rev rad 500 2 min rev
Force =
50.4 ft lbf torque = 403.2lbf = 1.5 ft radius of tool 12
36
Cutting Forces
Cutting (power) force: Fc
does the work of cutting (P = Fc x V)
Thrust force: Ft
perpendicular to cutting velocity pushes tool and work piece apart
37
Cutting Force Diagram
R Fc R Fs Ns
Ft
F V
38
Nomenclature
Ft = thrust force ( to cutting velocity) Fc = cutting force ( || to cutting velocity) N, F = Normal, tangent friction force of tool on chip Ns, Fs = Normal, tangent shear force of workpiece on chip = rake k angle l = shear angle = friction angle b = width of chip (into board)
Merchants Merchant s Force Circle

Fs Fc Ns Ft R
M. Eugene Merchant
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2009 1913 - 2006 40
Forces at Tool Face

F = Fc sin + Ft cos N = Fc cos - Ft sin F/N = (friction coefficient) : tan-1 =
F Ft + Fc tan = = N Fc Ft tan
Forces on Shear Plane

Fs = Fc cos - Ft sin Ns = Fc sin + Ft cos
42
Average Stresses on Shear Plane

Fs s = As Ns s = As bto As = = shear plane area sin
Average Stresses at Chip-Tool Interface

Difficult to determine, as there is no good method to estimate chip-tool g p contact length. It must be measured , which is difficult because after the cut, of chip curl.
44
Shear Angle ()
Based on Merchants analysis Find Fi d shear h angle l to maximize i i shear h stress Assuming ideal plasticity and independent of
not true
Fs s = As
Fs = R cos( + )
R = Fc sec( )
bt0 As = sin
Shear angle ()
Fs Fc sec( ) cos( + a ) sin s = = As bt0
d s = cos( + a ) cos sin ( + a ) sin = 0 d
hence
tan ( + ) = cot = tan (90 )

th f therefore
= 45 +
2
46
Shear angle ()
Lee and Shaffer (1951)
perfectly plastic material slip line analysis
Normal stress required to cause flow A =k

s
/4
k k D
Shear stress required to cause flow So, S s = s

s = k
/4 s

C
47
Shear angle ()
From Merchants circle
s k = tan ( + ) = = 1 s k
tan 1 (1) = ( + )
= 45 +
Shear angle ()
For a linear, linear strain hardening material
k = shear h stress t p = normal stress s = to/sin w = thickness of shear zone
ps
ps
kmax p k
0
s ps k w
w
s
49
Shear angle ()
Average normal stress on shear plane
Ns 1 s s = = ps k As 2w
to give average pressure
k = k max k0
Ratio of average pressure (s) to shear stress on the shear plane (s = kmax)
s Ns ps 1 s k = = tan ( + ) = s Fs k max 2 w k max

Shear angle ()
if we assume a perfectly plastic material
ps =1 k max
and
k = 0
tan ( + ) = 1
tan 1 (1) = ( + )
Lee and Shaffers Shaffer s result
= 45 +
3D Cutting (Oblique)
Z
n
X, V O
Vc
e
i Y
3-D Cutting g
i = inclination of tool to n = normal rake angle between z-axis z axis and OA e = effective cutting angle between Vc and line to V in plane V and Vc 1(sin2i + cos2i x sin ) e =sin sin-1 n
53
Temperature Rise
Assume: average chip-tool interface temperature rise (T) is a function of:
specific cutting energy (u) cutting speed (V) depth p of cut ( (to) (= ( feed for turning) g) thermal conductivity of workpiece (k) density y of workpiece p ( ) specific heat of workpiece (c)
Temperature Rise Dimensional Analysis

Two dimensionless groups result:
T c u
&
V to c V to = k
k = c
55
Temperature Rise Equation

Plotting data for many metals:
u T = 0.4 c
works for b/to > 5
1 Vto 3
56
Temperature Rise - Ex. Ex 6-1 61

Estimate the chip-tool chip tool interface temperature for: 302 stainless steel; HB = 200 kg/mm2 Cut on a lathe:
to = f (for turning) = 0.38 mm
feed rate = 0.38 mm/rev
b = d =2.54 mm V = 1.5 m/s


k = 16.2 W/m-K c = 500 J/kg J/kg-K K = 8000 kg/m3 6 m2/s = 4.05 4 05 x 10-6 /
u = 200 kgf/mm2 = 1.96 x 109 N/m2

Temperature p Rise - Ex. 6-3

to use T equation, check
1 Vto 3 1 1.5 0.38 103 3
b 2.54 = = 6.67 > 5 t0 0.38
u T = 0.4 c 1.96 109 = 0.4 8000 500 = 1020 K
4.05 10-6
59

Assuming room temperature = 20oC Then: T = T + 20 = 1040oC = 1313 K and Tmelt = 1421oC = 1694 K So we are at 80% of Tmelting, very HOT.
Limits on Temperature
Tool
most tools have a use limit, above which they degrade
Work piece
absolute limit is melting point other limits include combustion of chips chips, warpage of work piece
Model limitations
Assumptions
slow, orthogonal cutting constant material properties constant temperature simple sliding friction no strain hardening
Use analysis for:

trends and building intuition basis for detailed study
Summary
Chip formation mechanics
Power Energy Forces Torques Temperature
63
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Chip Formation Mechanics Power, Energy, Forces, Temperature

Idealized Chip Chip-formation formation Process

primary shear zone

tool V (cutting velocity)

Cutting Energy, Power, Forces & Torques

Specific Cutting Energy (u)

Cutting Work (W)

Work Power = Volume Volume time

Volume = MRR time

Cutting Power (P)

Cutting g Power ( (P) )

Where does cutting energy go?

u can be obtained in two ways Tabulated Estimated

Cutting Energy (u)

u us + uf us 0.75 0 75 - 0.8 08u

HB for heavily cold-worked metals o 3 1 2 2 4

What number to use?

u 1.5 us us (1/3 to 2/3) HB u (1/2 to 1) HB so, if no data, u HB

Comparison of Tensile and Cutting (Ex. 1-1)

Tension: Ex Ex. 1 1-2 2

Tension - Ex. Ex 1-3 13

( 185,000 ) (0.0816 )1.45 2 = (0.25) (6)

Cutting g - Ex. 1-4

uss 1.5 hp min/in3 x 550 x 60 x 12 = 594,000 594 000 in in-lbf/in lbf/in3

= 54,650 in-lbf (6,176 J)

Comparison - Ex. Ex 1-5 15

Turning vs vs. Orthogonal Cutting

Relation between u and t0

Turning Power and Force Force- Ex. Ex 2-1 21

Power - Ex. 2 2-2 2

Force - Ex. Ex 2-3 23

u vs vs. t0 in Turning Ex. Ex 3-1 31

u vs vs. t0 in Turning Ex. Ex 3-2 32

feed rate (mm/s)

u vs vs. t0 in Turning Ex. Ex 3-3 33

Force Ex. Ex 4-1 41

Force Ex. 4-2

4 4 Power = u MRR = 0.18 3.93 = 0.71 hp

Force Ex. Ex 4-3 43

Torque 18.6 ft lbf = 446.4lbf = drill bit radius 0.5in 1 ft 12in

Force Ex. Ex 4-4 44

Force Ex. Ex 5-1 51

Determine power, torque, and force

Force Ex. Ex 5-2 52

MRR = d b v = 0.2 4 5 = 4 in / min

Force Ex. Ex 5-3 53

50.4 ft lbf torque = 403.2lbf = 1.5 ft radius of tool 12

Cutting Force Diagram

Merchants Merchant s Force Circle

Forces at Tool Face

Forces on Shear Plane

Average Stresses on Shear Plane

Average Stresses at Chip-Tool Interface

tan ( + ) = cot = tan (90 )

Normal stress required to cause flow A =k

Shear stress required to cause flow So, S s = s

s Ns ps 1 s k = = tan ( + ) = s Fs k max 2 w k max

Temperature Rise Dimensional Analysis

Temperature Rise Equation