CUTTING FORCES IN TURNING PROCESS

Fn

SHEAR & NORMAL TO THE SHEAR FORCES:

Fs = Fc cosΦ - Ft sinΦ
Fn = Fc sinΦ + Ft cosΦ
FRICTION & NORMAL TO THE FRICTION FORCES:
F = Fc sinϒ + Ft cosϒ
N = Fc cosϒ - Ft sinϒ
GEOMETRY OF CHIP FORMATION:
• Chip thickness ratio (rc)
rc = t1/t2 = sinΦ/ cos (Φ-ϒ)
Uncut chip volume = chip volume
t1.l1.b1 = t2.l2.b2
where:
t1,t2 = Uncut chip and chip thickness
l1,l2 = Uncut chip and chip length
b1,b2 = Uncut chip and chip width
In orthogonal cutting process
b1= b2 ,so that.
t1.l1 = t2.l2
rc = t1/t2 = l2/l1
• Shear Angle (Φ):
Φ = 𝑡𝑎𝑛−1 (rc cosϒ/(1- rc sinϒ)).
 • Coeffictient of friction (µ) :
µ= F/N =tan β
= (Fc sinϒ + Ft cosϒ) / (Fc cosϒ - Ft sinϒ)
= (Fc tanϒ + Ft) / (Fc - Ft tanϒ)
• Velocity relationship:

V/ cos (Φ-ϒ) = Vc/ sinΦ = Vs/ cosϒ

Vc = V sinΦ / cos (Φ-ϒ) =V. rc
Vs = V cosϒ/ cos (Φ-ϒ) = VC cosϒ / sinΦ
• SHEAR NORMAL STRESSES:
τsh = Fs /As = Fs.sin Φ / b.t1
σn = Fn / As = Fn.sin Φ / b.t1
• SHEAR STRAIN:
ε= tan (Φ-ϒ) + cot Φ
ENERGIES & POWER RELATIONSHIP
 • SHEAR ENERGY:
Es =Fs.Vs /b.t1.V= τsh .ε

• FRICTION ENERGY:
Ef = F.Vc / b.t1.V = F.rc / b.t1

• CUTTING ENERGY:
It is also called specific cutting energy:
Ec =Fc.V/ b.t1.V = Fc / b.t1 = Es+Ef

CUTTING MOTOR POWER

• CUTTING POWER
Pc = Fc.V/61200
Where Pc (KW), Fc (N),V(m/min)
• MOTOR POWER
Pm = Pc /ɳov
Where:
ɳov = overall efficiency = ɳelec. ɳmech