Orthogonal & Oblique Cutting

Orthogonal and Oblique Cutting

•The two basic methods of metal cutting using a single point tool are the
orthogonal (2 D) and oblique (3D).

• Orthogonal cutting takes place when the cutting edge of the tool is 90
degree to the line of action of the tool(cutting velocity).

•If the cutting edge is inclined at an angle less than 90 degree to the line
of action of the tool, the cutting action is known as oblique.

Orthogonal Machining Oblique Machining

Orthogonal Cutting

Work

Feed

Tool

Orthogonal cutting
 Orthogonal Cutting
• The cutting edge of the tool remains at 900 to
the direction of feed (of the tool or the work)
• The chip flows in a direction normal to the
cutting edge of the tool
• The cutting edge of the tool has zero
inclination with the normal to the feed
• The chip flows in the plane of the tool face.
Therefore, it makes no angle with the normal
(in the plane of the tool face) to the cutting.
• The shear force acts on a smaller area, so
Work
shear force per unit area is more.

Feed

Tool
Orthogonal cutting

The tool life is smaller than obtained in oblique cutting (for same conditions of
cutting)
There are only two mutually perpendicular components of cutting forces on the tool.
Cutting Force and Thrust Force. So the metal cutting may be considered as a two
dimensional cutting.
The cutting edge is bigger than the width of cut.
Oblique Cutting

Work

Feed

Tool

Oblique cutting
 Oblique Cutting
• The cutting edge of the tool remains inclined at
an acute angle to the direction of feed (of the
work or tool)
• The direction of the chip flow is not normal to
the cutting edge. Rather it is at an angle β to
the normal to the cutting edge.
Work
• The cutting edge is inclined at an angle i to
the normal to the feed. This angle is called Feed
inclination angle.
Tool
• The chip flows at an angle β to the normal to
the cutting edge. This angle is called chip Oblique cutting

flow angle.

The shear force acts on a larger area, hence the shear force per area is smaller
The tool life is higher than obtained in orthogonal cutting
There are only three mutually perpendicular components of cutting forces on the
tool. Cutting Force, Radial force and Thrust Force or feed force. So the metal cutting
may be considered as a three dimensional cutting.
The cutting edge is smaller than the width of cut.
 Orthogonal Cutting Model
• As the material flows continuously in to chip and no
loss of material during plastic deformation , there is
no change in volume of the metal cut.
to wo Lo  tc wc Lc
• When t«b, the slide flow is negligible, hence wo  wc

to Lo  tc Lc

to Lc

tc Lo
 Chip thickness ratio (r)
or cutting ratio
to Lc
r 
tc Lo
Where, to = thickness of the chip prior to chip formation; and
tc = chip thickness after separation

• The chip thickness ratio (r) is the index of

the plastic deformation of the material
being machined.

• Chip thickness after cut is always greater

than before, so chip ratio is always
less than 1.0

• FIGURE .Schematic illustration of a two-dimensional cutting process (also

called orthogonal cutting).
 Shear Plane Angle(φ)
• Shear plane length = AC  to  tc
sin  cos(   )
Where α- rake angle of the tool
ф- shear angle
Hence,

to sin 
r
tc cos(   )
This equation can be solved for φ as

r cos 
tan  
1  r sin 
 Effect of Higher Shear Plane Angle
• Higher shear plane angle means smaller shear
plane which means lower shear force, cutting
forces, power, and temperature

Figure 21.12 Effect of shear plane angle  : (a) higher  with a resulting
lower shear plane area; (b) smaller  with a corresponding larger shear plane
area. Note that the rake angle is larger in (a), which tends to increase shear
angle according to the Merchant equation
 Chip Reduction Coefficient (ξ)
The inverse of chip thickness ratio is called as Chip reduction
coefficient (ξ)
1 tc Lo
  
r t o Lc
This factor, ξ, is an index of the degree of deformation
involved in chip formation process during which the thickness
of layer increases and the length shrinks.

Less value of ξ indicates less plastic deformation and require

less power consumption
Chip reduction coefficient (ξ) value increased when
larger rake angle
larger nose radius