PRODUCTION ENGINEERING

DEPARTMENT

Lecture 7:
Mechanics of Metal Cutting

2020-2021

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 PRODUCTION ENGINEERING
DEPARTMENT

Lecture 7:
Mechanics of Metal Cutting

2020-2021

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 Conditions for Metal Cutting Action PRODUCTION ENGINEERING
DEPARTMENT

There are four conditions for a cutting process to take

place:

1.Tool and workpiece in contact

2.Depth of cut
3.Relative motion
4.Chip formation

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 PRODUCTION ENGINEERING
Mechanics of a chipping process DEPARTMENT

▪ In all machining operations, two different models are generally adopted. These
are the oblique and the orthogonal cutting models, in which a single cutting edge
is used.

Slide 4
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Orthogonal Cutting vs Oblique Cutting DEPARTMENT

Straight turning
Oblique Cutting

Orthogonal Cutting

Straight turning

1- Cutting on a Planer 2- Tube Turning 3- Collar Turning

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Theory of Metal Cutting DEPARTMENT

• Two types describing the nature of the deformation zone in metal cutting:
• Thin Zone Model (Shear Plane).
• Thick Deformation Region (Shear Zone).
• Shear Plane is assumed to occur at high cutting speed.
• Shear Zone takes place at very low speeds.
• Thin Zone Model (Shear Plane) describes the practical cutting conditions.
• Therefore, it leads to more simple mathematical analysis (Orthogonal Cutting).

Chip Tool Tool

Chip

Workpiece Workpiece

Shear Plane Shear Zone

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Mechanics of a chipping process DEPARTMENT

Orthogonal Model with a well-defined shear Plane (Merchant Model)

Slide 7
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Orthogonal Cutting Model (Merchant Model) DEPARTMENT

Merchant investigated the orthogonal cutting

model. His analysis was based on the
following assumptions:
▪ Using a tool with a perfectly sharp cutting
edge and there is no contact along the
clearance face.
▪ The shear surface is a plane “AB”
extending upward from the cutting edge.
Shear plane is a plane of maximum shear
stress
▪ The cutting edge is a straight line
extending perpendicular to the direction of
motion.
▪ The depth of cut is constant.
▪ Small and uniform chip thickness of
continuous configuration with no BUE

Slide 8
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Merchant Circle (Force Diagram) DEPARTMENT

• Compact representation of the forces inside a circle.

• Reaction forces are concentrated at the tool point.
• Main cutting force Fv (in the direction of cutting speed V) and feed or tangential
force Ft (in the feed direction normal to Fv) can be measured using two
components dynamometer, since they are forces of known fixed directions.
• Resultant cutting force R can also be
resolved either in the direction of:
• Shear plane and perpendicular to it
(components Fs and Fns)
• Tool face and perpendicular to it
(components Ff and Fnt )
• The shear force Fs along the shear plane
and the normal force to shear plane Fns.
• The friction force Ff along the tool face and
Fnt normal to the tool face.
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Merchant Circle (Force Diagram) DEPARTMENT

Merchant Circle, can be constructed if the followings are known:

• Shear angle f
• Tool rake angle g
• Main cutting forces Fv
• Feed forces Ft

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Orthogonal Cutting DEPARTMENT

Terminology :
Fv = Main cutting force in direction of velocity v
Ft = Thrust or tangential force in the direction of feed f
Fs = Shear force in the direction of shear plane AB
Fns = Normal to shear force
Ff = Friction force
Fnt = Normal to friction force
R = Resultant cutting force
f = Shear angle
g = Rake angle
t = Chip thickness to be cut (feed f in mm/rev)
tc = Actual chip thickness
rc = Chip thickness ratio (Cutting Ratio) t/tc
 = Friction coefficient
Βf = Friction angle 11
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DEPARTMENT
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Merchant Circle (Force Diagram): Procedure DEPARTMENT

1. Set-up a X-Y axis.

2. Using a drawing scale (for example, 100N=1cm, so
that a 500N force is drawn as a 5cm line):
a) Draw the cutting force (Fv) horizontally.
b) Draw the tangential force (Ft) vertically.

3. Draw the resultant force (R) of Fv and Ft.

4. Locate the center of the R.

5. From this center, draw a circle with a diameter =R.

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 PRODUCTION ENGINEERING
Merchant Circle (Force Diagram): Procedure DEPARTMENT

6. Draw the cutting tool by considering the rake angle (g) from the vertical axis.

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 PRODUCTION ENGINEERING
Merchant Circle (Force Diagram): Procedure DEPARTMENT

7. Sketch the friction force (Ff) by extending the line representing the tool face
(at the same rake angle) through the circle.
8. Draw a line from the end of the Ff to the resultant force (R).
This gives the normal to friction force (Fnt).

The angle between Fnt and R is called friction angle (βf) 15

 PRODUCTION ENGINEERING
Merchant Circle (Force Diagram): Procedure DEPARTMENT

9. Draw the shear force (Fs) by drawing a line from the origin point with an
inclination angle to the horizontal axis equals the shear angle (Φ).
10. Draw a perpendicular line from the Fs to the R.
This line is the normal to shear force (Fns).

F
f
tan  = =
f F
nt
μ: Coefficient of Friction

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11. Use a ruler and a protractor to measure all the distances and the angles.
 PRODUCTION ENGINEERING
Merchant Analysis DEPARTMENT

Resultant Force

R= F 2+F 2 = F 2 +F 2 = F 2 +F 2
v t s ns f nt N

Forces

F = F cos f − F sin f N
s v t

F = F cos f + F sin f N
ns t v

F = F sin g + F cos g N
f v t

F = F cos g − F sin g N
nt v t

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 PRODUCTION ENGINEERING
Merchant Analysis DEPARTMENT

F
 
tan f +  − g  = ns
 f  F
s

F = F tan f +  − g  N
ns s  f 
F
f
tan  = =
f F
nt
F = F sin g + F cos g N
f v t
F = F cos g − F sin g N
nt v t
F sin g + F cos g
= v t
F cos g − F sin g
Divide by cos g
v t βf : Friction angle
F + F tan g μ : Coefficient of friction between the chip
= t v
F − F tan g and the tool face
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v t
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Shear Angle Calculations DEPARTMENT

• Let t, l, and b denotes the thickness, length, and the width of the uncut chip respectively.
• The corresponding dimensions of the cut chip are tc, lc, and bc.
• During machining it is assumed that the change of density is negligible.
• Thus, the volume of the uncut chip is equal to that of the cut chip: t.l.b = t .l .b
• Assuming a negligible change in chip width during orthogonal cutting, hence
c c c
t .l = t .l
c c
• The (Cutting Ratio) rc becomes: l
t c
= = r
c
t l
c
• The length of the shear plane AB (Ls) which is given by:
t t
L = = c
sin f cos(f − g )
s

t sin f
r = =
c
t cos(f − g )
c
• Where, ɸ is the shear angle.  r cos g 
− 1 c 
f = tan  
 1 − r sin g 
 c  19
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Shear Stress Calculations DEPARTMENT

• At the shear plane, the two components of forces Fs and Fns can be used to
calculate the mean shear stress t and normal stress s on the shear plane:
F F
t= s s = ns
b

A A
s s t Ls
φ
b.t
• Where, As is the area of the shear plane: A = b.L =
s s
sin f
• Where, b is the width of cut and t is the un-deformed chip thickness.

( F cos f − F sin f ) sin f ( F sin f + F cos f ) sin f

t = v t
s = v t
b.t b.t
N/mm2
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Velocity Relations DEPARTMENT

V Cutting speed velocity is the velocity of the W.P relative to the cutting tool (in the direction of the
tool movement).
Vs Shear velocity is the velocity of the chip relative to the W.P (in the direction of the shear plane)
Vc Chip Velocity is the velocity of the chip relative to the tool ( in the direction of the tool face)

V . cos g V . sin f
V = m/min V = =r V m/min
c c
s
cos(f − g ) cos(f − g )

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Power Consumption DEPARTMENT

The power consumption in the cutting, shearing metal and friction along the tool
face can be calculated based on the forces (N) and velocities (m/min) found earlier
as follows: F .V
• Cutting Power: N = v kW
c 60000
Fs .Vs
• Shearing Power: N = kW
s 60000
F .Vc
f
• Friction Power: N = kW
f 60000

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Solved Example DEPARTMENT

Example:
During an orthogonal machining operation with a cutting tool having 10 degrees rake
angle, the chip thickness was measured and found to be 0.4 mm, the un-deformed chip
was 0.15 mm. Determine the shear plane angle analytically and graphically.

g = 10o
tc = 0.4mm
t = 0.15mm

rc cos g
tan f =
1 − rc sin g
t 0.15
rc = = = 0.375
tc 0.4
(0.375) cos 10
f = tan −1
= 21.5o
1 − (0.375)(sin 10)
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Solved Example DEPARTMENT

▪ In an orthogonal cutting operations for turning a given steel tube using a

tool with a rake angle = -10˚ , the shear force, the frictional force and the
shear angle could be estimated to be 300 N, 200 N and 40 ˚,respectively.
Calculate the values of:
1.Main cutting force.
2.Thrust force
3.Coefficient of friction.

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Graphical Solution DEPARTMENT

3 cm

2 cm

▪ Main Cutting Force (Fv)= 659. 63 N Scale 1: 100

▪ Thrust force (Ft)= 319.4 N
▪ Coefficient of Friction = 0.283726
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▪ Friction angle =15.84 ˚
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Analytical Solution DEPARTMENT

F = F cos f − F sin f F = F sin g + F cos g

s v t f v t
300 = F cos 40 − F sin 40 200 = F sin − 10 + F cos − 10
v t v t
300 = 0.766 F − 0.643 F 200 = −0.174 F + 0.98F
v t v t
F = 321.5 N
t
F = 661.5 N
v
F + F tan g
= t v
F − F tan g
v t
321.5 + 661.5 tan (− 10)
= = 0.2852
661.5 − 321.5 tan (− 10)
tan − 1( ) = tan − 1(0.2852) = 15.92
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