Faculty of Engineering

Mechanical Engineering Dept. 3rd Year production engineering.

Benha M1371 theory of metal cutting
University Instructor: Dr. Ashraf Hassan Laboratory
experiments.

Experiment No (3)

Effect of speed and feed in orthogonal machining

Introduction
In the machining of metals, changes in cutting speed and feed produce certain
important effects. These effects can be measured in terms of a number of parameters,
namely,
The specific cutting energy𝑷𝒔 , the work in cutting per unit volume of material
𝑭𝑪
removed, which is given by𝑷𝒔 =
𝑨𝒄

Where 𝐹𝑐 the cutting component of the resultant tool is force, and 𝑨𝒄 is the cross-
sectional area of the uncut chip.
The cutting ratio𝑟𝑐 , which is given by
𝒂𝒄
𝒓𝒄 =
𝒂𝟎
Where 𝑎𝑐 is the unreformed chip thickness, and 𝑎0 is the chip thickness
The mean angle of friction on the tool face β, which can be obtained from
𝑭𝒕
= 𝐭𝐚𝐧( 𝛃 − 𝜸𝒏𝒆 )
𝑭𝒄

Where 𝜸𝒏𝒆 is the working normal rake, and 𝑭𝒕 is the thrust component of the resultant
tool face,
The apparent sear strength of the work material 𝝉𝒔 , which is the shear stress on the
shear plane and is given by
(𝑭𝒄 𝐜𝐨𝐬 ɸ − 𝑭𝒕 𝐬𝐢𝐧 ɸ) 𝐬𝐢𝐧 ɸ
𝝉𝒔 =
𝑨𝒄
Where ɸ is the shear angle and is given by

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 𝒓𝒄 𝐜𝐨𝐬 𝜸𝒏𝒆
𝐭𝐚𝐧 ɸ =
𝟏 − 𝒓𝒄 𝐬𝐢𝐧 𝜸𝒏𝒆
Equipment
1. Lathe
2. tubular workpiece of 85/15 brass
3. Two-component cutting force dynamometer and necessary recording
equipment
4. High-speed steel cutting tool with a 25° normal rake

Procedure
The measurement of the thickness of the chip produced during each test can
be made with a ball micrometer if the chip is reasonably straight and has smooth
surfaces If the chip is not straight and does not have smooth surfaces, chip
thickness can be estimated by weighing a sample length of chip and using the
expression
𝒎
𝒂𝟎= 𝒄
𝝆𝒍𝒄 𝒂𝒘

𝒎𝒄 = mass of the chip sample

𝒍𝒄 = length 0f the chip sample
𝒂𝒘 =width of the chip
𝝆=density of the work material
Finally the specific cutting energy 𝒑𝒄 , the cutting ratio 𝒓𝒄 , the mean angle of

friction on the tool face β, and the apparent shear strength of the work material
𝝉𝒔 , are calculated from Eqs. Each of these factors ls
then plotted against the logarithm of the cutting speed (log V) for each value of
undeformed chip thickness𝒂𝒄 and against 𝒂𝒄 for each value of v.

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