EXPERIMENT-3

AIM-
To study the effect of cutting speed, feed and depth of cut on shear angle and also study the
relationship of chip thickness ratio and shear angle.

MATERIALS REQUIRED-
Workpiece with diameter 29mm, Lathe, Scale, Measuring Thread, Slot width groove of 3mm and 7
degree rake angle, Tool Material: High Speed Steel

THEORY-

The orthogonal Cutting Model

The machining process is a complex 3D operation. A simplified 2D model of machining
is available that neglects many of geometric complexities, yet describes the process
quite well. Orthogonal cutting uses a wedge-shaped tool in which the cutting edge is
perpendicular to the cutting direction. As the tool is forced into the material, the chip is
formed by shear deformation along shear plane oriented at an angle φ (shear angle)
with the surface of the workpiece. Along the shear plane, plastic deformation of work
material occurs.
The tool in orthogonal cutting has two main elements of geometry:
(1) rake angle and
(2) clearance angle. The rake angle α determines the direction of chip flow as it is
formed; and the clearance angle provides a small clearance between tool flank and
newly generated work surface.

Chip Thickness Ratio:

r = t1/t2
t1 = chip thickness prior to deformation.(uncut chip thickness)
t2 = chip thickness after deformation(cut chip thickness)

As the chip is formed along the shear plane, its thickness increases to t2.
The ratio of t1 to t2 is called chip thickness ratio and is always less than 1.

Also, t1 . L1 = t2 . L2
Where L1 = length of metal before cut
L2 = length of chip
Volume of cut = Volume of uncut
i.e r = t1/t2 = L2/L1

An important relationship between chip thickness ratio, rake angle and shear plane angle is.
𝑟 cos 𝛼
tan 𝜑 =
1 − 𝑟 sin 𝛼
Where,
𝜑 = 𝑠ℎ𝑒𝑎𝑟 𝑝𝑙𝑎𝑛𝑒 𝑎𝑛𝑔𝑙𝑒
𝑟 = 𝑐ℎ𝑖𝑝 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑎𝑡𝑖𝑜
𝛼 = 𝑟𝑎𝑘𝑒 𝑎𝑛𝑔𝑙𝑒
PROCEDURE-

(1) Workpiece mounted on the lathe machine is provided with a groove of 3 mm. Workpiece is
made to revolve at a slow speed and tool is fed against the work so that chip material is removed.

(2) Collect the chips as soon as chips are generated.

(3) Measure the length of the chips using a thread.

(4) After obtaining the chip thickness ratio, calculate the shear angle using the above mentioned
relationship.

(5) Plot the graphs using the table to understand the relationship between different cutting
parameters.

OBSERVATIONS AND CALCULATIONS-

Initial Diameter of the workpiece= 29 mm
Groove Size = 3 mm
Rake Angle = 7 degrees
Length of metal before cut, L1(for one revolution) = (Π D – Groove Size) in mm
= ( Π (29) – 3) mm = 88.06 mm

Where D = Initial diameter of workpiece in mm

Length of chip (L2) is measured using a thread and a scale.

The chip thickness ratio of L2 and L1 is calculated and organised in a table for various parameters.

The values of shear angles is also tabulated using the relationship between chip thickness ratio,
shear angle and the rake angle.
𝑟 cos 𝛼
tan 𝜑 =
1 − 𝑟 sin 𝛼

Observations Table 1-

Depth of Cut = 1
Feed = 0.227 mm/rev mm
Sno N(RPM) L2 (mm) L1 (mm) Chip Thickness Ratio Shear Angle
1 421 35 88.06 0.39745628 22.5176623
2 270 40 88.06 0.454235748 25.51376174
3 182 42 88.06 0.476947536 26.68440392

Observations Table 2-

Feed = 0.227 mm/rev N = 270 rpm

Sno Depth of Cut (mm) L2 (mm) L1 (mm) Chip Thickness Ratio Shear Angle
1 1 40 88.06 0.454235748 25.51376174
2 0.8 37 88.06 0.420168067 23.72756702
3 0.6 32 88.06 0.363388599 20.67616366
Observations Table 3-

Depth of Cut = 1
N = 270 rpm mm
Sno Feed (mm/rev) L2 (mm) L1 (mm) Chip Thickness Ratio Shear Angle
1 1 45 88.06 0.511015217 28.40857097
2 0.8 43 88.06 0.488303429 27.26343718
3 0.6 40 88.06 0.454235748 25.51376174

Plots of various cutting parameters-

Various cutting parameters are plotted using Microsoft Excel .

The plots obtained are as below-

Shear Angle and Chip Thickness Ratio vs RPM

30

26.68440392
25.51376174
25
22.5176623
Shear Angle and Chip Thickness Ratio

20

15

10

0.39745628 0.454235748 0.476947536

0
421 270 182
RPM

Shear Angle Chip Thickness Ratio

 Shear Angle and Chip Thickness Ratio vs Depth of Cut
30

25.51376174
23.72756702
25
Shear Angle and Chip Thickness Ratio

20.67616366

20

15

10

0.454235748 0.420168067 0.363388599

0
1 0.8 0.6
Depth of Cut

Chip Thickness Ratio Shear Angle

Shear Angle and Chip Thickness Ratio vs Feed

35

30 28.40857097
27.26343718
Shear Angle and Chip Thickness Ratio

25.51376174

25

20

15

10

0.511015217 0.488303429 0.454235748

0
1 0.8 0.6
Feed

Chip Thickness Ratio Shear Angle

Results-

On analysing the plots, we see the proportional relationships between different cutting parameters.

(1) Shear Angle and Chip Thickness Ratio decreases for increase in RPM (inversely
proportional).
(2) Shear Angle and Chip Thickness Ratio increases for increase in depth of cut (directly
proportional).
(3) Shear Angle and Chip Thickness Ratio increases for increase in feed rate (directly
proportional).

Precautions-

(1) The lathe must be run at optimal conditions for productions of continuous chips.
(2) Must be careful while measuring the length of chip after cut as it is non-uniform and a
thread must be used to measure the chip length accurately.
(3) Must be careful while operating the lathe machine.