Orthogonal Cutting Tests

NOTE: See second tab in excel sheet for "total chip length", "total chip weight" and "chip thickness" values
Test Date:
Performed by:
Test Machine:
Coolant: none
Testing Purpose: Cutting Coefficients Dmid (mm) 38.820
Rake Angle (deg): 0 In radian 0
Relief Angle (deg): 7 In radian 0.122173048
Depth of cut b [mm]: 1.780 In inch 0.070078778
Cutting Speed V [m/min]: 100 In rpm 820
Material: MATERIAL X Specific density [gr/mm^3]: 0.0077324
Software: MalDAQ
Frequency [Hz] / Number of Samples: 12800
Magnification Factor [N/V]: 100
Filter: none
Feed Rate Total Chip Length Total Chip Weight Measured Measured Chip Thickness
Test No: h [mm/rev] [mm] [gr] Ftc [N] Ffc [N] hc [mm]
1 0.040 13.30 0.0384 318 370 0.2260
2 0.080 15.94 0.0697 466 481 0.3370
3 0.120 15.17 0.0834 615 566 0.4291
4 0.160 10.50 0.0676 739 637 0.5096
5 0.200 21.72 0.1806 884 722 0.6564
6 0.240 20.35 0.1779 953 693 0.6830
Average

Tangential Cutting force coefficient, Ktc

Feed Cutting Force Coefficient, Kfc
T a n g e n tia l a n d F e e d F o r c e s [N ]

Tangential Edge Cutting Force Coefficient, Kte

Feed Edge Cutting Force Coefficient, Kfe
A= 3512.5
B= 182.9
C= 2150.0
D= 297.2
b= 1.780

Ft=Ftc+Fte V= 100 [m/min], b=1.78 [mm], alpha_r=0 (deg)

Ftc=Ktc*b*h =Ah
1000
Fte=Kte*b=B
900
800 f(x) = 3512.5 x + 182.9
Tangential Forc
Kte=B/b= 102.75 700
f(x) = 2150 x + 297.2 Linear (Tangent
Ktc=A/b= 1973.31 600 Feed Force
500 Linear (Feed Fo
400
Ff=Ffc+Ffe
300
Ffc=Kfc*b*h=Ch
200
Ffe=Kfe*b=D 100
0
Kfc=C/b= 1207.87 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20 0.22
Feed rate [mm/rev]
Kfe=D/b= 166.97
 Edge Force Fte [N]= 182.90
Edge Force Ffe [N]= 297.20

Chip Ratio Shear Angle Friction Angle Shear Stress

rc phi_c (deg) beta_a (deg) tau_s [MPa]
0.1770 10.0 28.3 294.6
0.2374 13.4 33.0 377.9
0.2797 15.6 31.9 433.4
0.3140 17.4 31.4 451.0
0.3047 16.9 31.2 447.7
0.3514 19.4 27.2 462.0
0.28 15.5 30.5 411.1

1973.31 [N/mm^2]
1207.87 [N/mm^2]
102.75 [N/mm]
166.97 [N/mm]

=0 (deg)

Tangential Force
Linear (Tangential Force)
Feed Force
Linear (Feed Force)

0.22
 Chip Ratio Averages
Specific Density 0.0077324
MATERIAL X
Rake 0 / Relief 7 Speed 100 m/min Feed Chip L1 Chip L2 Chip L3
Depth of Cut 1.78 mm 0.04 3.62 4.75 4.93
Coolant No 0.08 5.97 5.89 4.08
0.12 6.37 3.78 5.02
0.16 3.16 3.56 3.78
0.20 6.16 9.76 5.8
0.24 5.51 5.79 9.05
Chip W1 Chip W2 Chip W3 Chip Th1 Chip Th2 Chip Th3 p Th AVRG Rat AVRG Total L Total W
0.0106 0.0145 0.0133 0.1049 0.304174 0.268815 0.225963 0.17702 13.30 0.0384
0.0273 0.0251 0.0173 0.16382 0.424626 0.422507 0.336984 0.2374 15.94 0.0697
0.0354 0.0208 0.0272 0.199087 0.548302 0.5399 0.429096 0.279658 15.17 0.0834
0.0193 0.0226 0.0257 0.218801 0.632567 0.677469 0.509612 0.313964 10.50 0.0676
0.0487 0.0832 0.0487 0.283222 0.849418 0.83666 0.656433 0.304677 21.72 0.1806
0.0471 0.0488 0.0820 0.30623 0.839826 0.902845 0.682967 0.351408 20.35 0.1779