Tool Engineering

Tool Engineering

Mechanics of Metal Cutting

Dr Wang Hao, Victor

Assistant Professor
Department of Mechanical Engineering
EA-02-05 / 6516 2207 / mpewhao@nus.edu.sg
Tool Engineering

Terms and definitions

Tool has a wedge shape and a
straight cutting edge.

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Tool Engineering

Terms and definitions

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Tool Engineering

Chip formation
Continuous chips

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Tool Engineering

Chip formation

Discontinuous chips
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Tool Engineering

Chip formation
Speed ranges for segmented chip formation

(Adapted from Komandhuri, R., et al., Trans. ASME, J. Eng. Ind., Vol. 104, 121–131, 1982.) 6
Tool Engineering

Chip formation
Effect of cutting speed on separation of chip segments

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Tool Engineering

Strain-gauge load cell

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Tool Engineering

Force measurement
Piezoelectricity

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Tool Engineering

Force measurement
Turning:

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Tool Engineering

Force measurement
Turning:

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Tool Engineering

Force measurement
Milling:

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 Tool Engineering

Specific cutting energy

The
  rate of energy consumption
during machining is
Specific cutting energy is an
indication of machining efficiency,
independent of v:

Effect of cutting speed and undeformed chip

thickness on specific cutting energy, where
ps = specific cutting energy, v = cutting
speed, and ac = undeformed chip thickness
and the material is mild steel, the normal
rake is 10 degrees. and the width of the chip
is 1.25 mm.
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 Tool Engineering

Ploughing force
The force acting on the
tool edge and the force
that may act on the tool
flank do not contribute to
removal of the chip. These
forces will be referred to
collectively as the
ploughing force Fp.

Contact regions on a cutting tool, where Fr =

resultant tool force, F’r = force required to
remove chip, and Fp = ploughing force acting on
the tool edge and work-tool interface region.
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 Tool Engineering

Size effect

Effect
  of maximum
undeformed chip
thickness on specific
cutting energy during
slab milling, where the
material is steel, 57
ton/in.2, UTS.

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Tool Engineering

Mean shear strength

Shear-plane model of continuous chip formation:

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Tool Engineering

Mean shear strength

The
  length of the shear plane:
(1)

(2)
The cutting ratio , (3)
In experimental work, and can be measured or obtained from the weight
of a known length of chip as

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Tool Engineering

Mean shear strength

The
  force to shear the work material:

The area of shear:

The apparent shear strength of the material on the shear plane:

calculated in this way, remains constant for a given work material over a
wide variety of cutting conditions.

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Tool Engineering

Theory of Ernst and Merchant

• The chip is assumed to
behave as a rigid body
held in equilibrium by the
action of the forces
transmitted across the
chip-tool interface and
across the shear plane.
• The chip remains straight
and has infinite contact
length with the tool face.
• The whole of the resultant
tool force is transmitted
across the chip-tool
interface and that no
additional force acts on the
tool edge or flank (i.e., the
ploughing force is zero).
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Tool Engineering

Theory of Ernst and Merchant

Fr: resultant tool force
acting at the tool cutting
edge and is resolved into
components
Fn and Ff in directions
normal to and along the
tool face, respectively,
Fns and Fs normal to and
along the shear plane,
respectively.
The cutting (Fc) and thrust
(Ft) components of the
resultant tool force

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 Tool Engineering

Theory of Ernst and Merchant

The
  basic of E-M theory suggests
that the shear angle would take
up such a value as to reduce the
work done in cutting to a
minimum.
The work done in cutting is
proportional to .

Force diagram for orthogonal cutting, where Fr

= resultant tool force, Fc = cutting force, Ft =
thrust force, Fs = shear force on shear plane,
Ff = frictional force on tool face, Fn = normal
force on tool face, φ = shear angle, γne =
working normal rake, β = mean friction angle
on tool face, ac = undeformed chip thickness,
and ao = chip thickness.
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 Tool Engineering

Theory of Ernst and Merchant

 

where
shear strength of the work material on the
shear plane
area of shear plane
cross-sectional area of uncut chip
mean angle of friction between chip and
tool (given by )
working normal rake

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Tool Engineering

Example 1
In an experimental turning operation where low-carbon steel was being machined using a
carbide tool, the following data were taken:
Cutting force Fc = 1 kN
Thrust force Ft = 0.5 kN
Working normal rake γne = 20 degrees
Feed f = 0.141 mm
Working major cutting-edge angle κ r = 45 degrees
Depth of cut (back engagement) ap = 5 mm
Cutting speed v = 2 m/s
Cutting ratio rc = 0.2
Workpiece diameter dw = 100 mm
Workpiece machined length lw = 300 mm
Estimate from the data given:
a. The specific cutting energy of the work material p s
b. The power required for machining Pm
c. The undeformed chip thickness ac
d. The width of cut aw
e. The shear angle φ
f. The mean angle of friction on the tool face β
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g. The time taken to complete the machining operation
Tool Engineering

Example 2
Show
  that in metal cutting when the working normal rake is zero, the ratio
of the shear strength of the work material to the specific cutting energy is
given by

where μ is the coefficient of chip-tool friction, and is the cutting ratio.

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Tool Engineering

Example 3
A slab milling operation is being carried out with a 100-mm
diameter milling cutter having 8 teeth at 30 m/min. The depth
of cut is 4 mm and table feed rate is 150 mm/min. The width of
the workpiece is 120 mm. Find the average cross-sectional
area of the undeformed chip.

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Tool Engineering

Example 4
 In turning of a slotted pipe of diamond 90 mm, the chip
produced was 125-mm long. If , determine the length of the
shear plane.

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