Rajshahi University of Engineering and Technology (RUET) Rajshahi-6204

Department of Mechatronics Engineering

ME 2255

Manufacturing
Process

3/15/2021 1
 Rajshahi University of Engineering and Technology (RUET) Rajshahi-6204
Department of Mechatronics Engineering

Lecture on
Manufacturing Process
Md. Robiul Islam
Assistant Professor
Department of Mechatronics Engineering
Rajshahi University of Engineering and Technology (RUET)
Rajshahi-6204

3/15/2021 2
3/15/2021 3
3/15/2021 4
3/15/2021 5
3/15/2021 6
3/15/2021 7
3/15/2021 8
3/15/2021 9
3/15/2021 10
3/15/2021 11
3/15/2021 12
 Manufacturing Process
Similarities between rake angle and clearance angle
• Rake angle and clearance angle are two important angles of every cutting tool. So their
presence in every cutter is mandatory.
• These two angles are independent to each other. However, their algebraic sum with wedge
angle must be equal to 90°.
• Every cutting tool should have pre-defined values for rake angle and clearance angle for
efficient and uninterrupted machining with better machinability.
• Based on the direction of measurement, values of these angles will change.
• Values of both the angles in different directions or planes are absolutely necessary while
fabricating or re-sharpening the cutter.
• Both the angles may change due to gradual wear of cutting tool.

3/15/2021 13
 Manufacturing Process

3/15/2021 14
3/15/2021 15
 𝑉 = 𝜋𝐷𝑁/1000 = 𝑚/𝑠

3/15/2021 16
Determine the cutting speed in machining a work piece of 200 mm
diameter rotating at a speed of 100 rpm. Also calculate machining
time if work piece length is 0.5 m and feed is 0.45 mm/rev.

Solution:
Given that
Diameter of the job, D=200 mm
Speed, N= 100 rpm
Feed, f=0.45 mm/rev
Length of the job, L=0.5 m=500 mm

We know that,
𝜋𝐷𝑁 𝜋×200×100
Cutting Speed,𝑉 = 1000 = 1000 = 62.83 𝑚/𝑚𝑖𝑛 (Ans)

𝐿 500
Machining Time, 𝑇𝑚 = 𝑓𝑁 = 0.45×100 = 11.11 𝑚𝑖𝑛 ≈ 12 𝑚𝑖𝑛 (Ans)

3/15/2021 17
A cylindrical work part 125 mm in diameter and 900 mm long is to be turned in an
engine lathe. Cutting conditions are: V= 2.5 m/s, f=0.3 mm/rev, and d=2.0 mm.
Determine a) Cutting time, and b) Metal removal rate.
Solution:
Given that, D= 125 mm, L= 900 mm , V= 2.5 m/s= 2500 mm/s, f=0.3 mm/rev , d=2.0
mm
𝑣 2500
We know that, Speed, 𝑁 = = = 6.366 𝑟𝑒𝑣/𝑠
𝜋×𝐷 𝜋×125

𝑚𝑚
𝑓𝑟 = 𝑁 × 𝑓 = 6.366 × 0.3 = 1.9098 = 1.9098 × 60 = 114.588 𝑚𝑚/𝑚𝑖𝑛
𝑠
𝐿 900
a) 𝑇𝑚 = 𝑓 = 114.588 = 7.85 𝑚𝑖𝑚
𝑟

b) 𝑀𝑅𝑅 = 𝑣𝑓𝑑 = 2500 × 0.3 × 2 = 1500 𝑚𝑚3 /𝑠

3/15/2021 18
3/15/2021 19
3/15/2021 20
Single Point Cutting Tool Advantages:
The main advantages are:
1. Design and fabrication are easy.
2. This tool is a little cheaper in price.
Single Point Cutting Tool Disadvantages:
The main disadvantages are:
1. There is having little high tool wear rate.
2. Shorter tool life.
3. Low metal removal rate.
4. Low productive.

3/15/2021 21
Single Point Cutting Tool Application:
This tool is used in several machines for producing a flat surface like:
• Lathe machine, Shaper Machine and more.
Materials used for Single Point Cutting Tool
This tool can be made from several materials like:
• High carbon steel
• High-speed steel
• Ceramics
• Diamonds
• Cemented carbide
• CBN (Cubic boron nitrite)

3/15/2021 22
 Manufacturing Process

Single Point Cutting Tool Geometry / Nomenclature:

1. Shank Angle:
2. Flank 1. Side Cutting edge angle
3. Face 2. End cutting edge angle
4. Heel 3. Side relief angle
5. Nose 4. End relief angle
6. Nose radius 5. Back Rack angle
7. Cutting Edges 6. Side rack angle

3/15/2021 23
3/15/2021 24
3/15/2021 25
3/15/2021 26
3/15/2021 27
3/15/2021 28
 Chip Formation:
Process: A wedge shaped single point cutting tool moves relative to the work piece. As the
tool makes contact with the metal, it exerts pressure on it. Due to these compressive forces
shear stresses are induced on the work piece. Whenever and wherever the value of the shear
stress reaches or exceeds the shear strength of that work material in the primary deformation
region, yielding or slip takes place. This results in shear deformation in that region and in the
plane of maximum shear stress.

3/15/2021 Fig: The possible deformations in metal cutting 29

A chip is produced ahead of the cutting tool by first elastic deformation or
yielding and then finally by plastic deformation and shearing the material
continuously, along the shear plane. But the forces causing the shear stresses
in the region of the chip quickly diminishes and finally disappears while that
region moves along the tool rake surface towards the secondary shear zone
and then goes beyond the point of chip-tool engagement.

As a result the slip or shear stops propagating long before total separation
takes place. In the meantime the succeeding portion of the chip starts
undergoing compression followed by yielding and shear. This phenomenon
repeats rapidly resulting in formation and removal of chips in thin layer by
layer.
3/15/2021 30
 Manufacturing Process
Conditions of chip formation: Different types of chips are produced
depending on the material being machined and the cutting conditions. These
conditions include:
• Type of cutting tool used.
• Speed and rate of cutting.
• Tool geometry and cutting angles.
• Condition of machine.
• Presence/Absence of cutting fluid, etc.
• The study of chips produced are very important because the type of chips
produced influence the surface finish of the work piece, tool life, vibrations, chatter,
force and power requirements, etc.

3/15/2021 31
 Manufacturing Process
Types of Chips
Basically, there are four types of chips commonly observed in practice
• Continuous chips
• Continuous chips with built-up edge
• Serrated or segmented chips
• Discontinuous chips

3/15/2021 32
 Manufacturing Process

3/15/2021 33
 Manufacturing Process

3/15/2021 34
 Manufacturing Process

3/15/2021 35
3/15/2021 36
3/15/2021 37
3/15/2021 38
3/15/2021 39
3/15/2021 40
3/15/2021 41
 Manufacturing Process

Tool Wear
DEFINITION: Gradual failure of cutting tools due to regular operations is known
as tool wear.
MODES OF CUTTING TOOL FAILURES:

FRACTURE FAILURE:
• This mode of failure occurs due to mechanical breakage due to excessive
forces and shocks at the tool point causing it to fail suddenly by brittle fracture.
• Also known as mechanical chipping.
• Such kind of tool failure is random and catastrophic in nature, results in
premature loss of tool and hence is extremely detrimental.

3/15/2021 42
 Manufacturing Process
TEMPERATURE FAILURE:
• This failure occurs when the cutting temperature is too high for the tool
material, causing the material at the tool point to soften, which leads to plastic
deformation and loss of the sharp edge.
• This type of failure also occurs rapidly, results in premature loss of tool and is
quite detrimental and unwanted.
Note: Both of the above kinds of tool failure need to be prevented by using
suitable tool materials and geometry depending upon the work material and cutting
condition.

3/15/2021 43
 Manufacturing Process

GRADUAL WEAR:

• Gradual wearing of the cutting edge causes loss of tool shape, reduction in

cutting efficiency, an acceleration of wearing as the tool becomes heavily worn,

and finally tool failure in a manner similar to a temperature failure.

• Gradual wear is preferred because it leads to the longest possible use of the

tool, option of changing the tool before the final catastrophic loss of the cutting

edge occurs, with the associated economic advantage of that longer use.

3/15/2021 44
3/15/2021 45
3/15/2021 46
TOOL LIFE:
• Useful life of a tool expressed in terms of time from start of a cut to
termination point (defined by failure criterion). Sometimes also
expressed in terms of no. of the parts machined.
Tool failure criterion depends on
1. The requirements of the component being produced.
2. Type of Operation:
• Roughing: force and power requirement.
• Finishing : Surface finish & dimensional accuracy.

3/15/2021 47
3/15/2021 48
3/15/2021 49
3/15/2021 50
Problem: If in turning of a steel rod by a given cutting tool (material
and geometry) at a given machining condition (feed and depth of
cut) under a given environment (cutting fluid application), the tool
life decreases from 80 min to 20 min. due to increase in cutting
velocity, V from 60 m/min to 120 m/min., then at what cutting
velocity the life of that tool under the same condition and
environment will be 40 min.?

Solution: Taylor’s tool life equation as 𝑽𝑻𝒏 = 𝑪 𝐴𝑔𝑎𝑖𝑛

Now, 𝑉1 𝑇1 = 𝑉2 𝑇2 = 𝑉3 𝑇3 =…….=C
𝑉3 𝑇3 𝑛 =𝑉1 𝑇1 𝑛
Here, 𝑉1=80 m/min, 𝑇1 =80 min
𝑛
𝑉2 =120 m/min, 𝑇2 =20 min 𝑉3 𝑇1
=
𝑉3 =? (To be determined) 𝑉1 𝑇3
Now, 𝑉1 𝑇1 𝑛 =𝑉2 𝑇2 𝑛 𝑉3 =?
𝑇1 𝑛 𝑉2
𝑇2
=𝑉 , n=?
1

3/15/2021 51
3/15/2021 52