FUNDAMENTALS

OF METAL
CUTTING AND
THEORY OF
MACHINING
Overview of
Machining
• Machining: term applied to all material-
removal processes
• Metal cutting:
• the process in which a thin layer of excess
metal (chip) is removed by a wedge-shaped
single-point or multipoint cutting tool with
defined geometry from a workpiece, through a
process of extensive plastic deformation
Schematic of Metal Cutting Process and Terminology
machined
surface
work
surface
primar

cutting
tool
• Abrasive processes: material
removal by the action of hard,
abrasive particles that are usually
in the form of a bonded wheel.
Each single particels acts as a
single point cutting tool. Since the
particular geometry of a particle is
not known, abrasive processes are
referred to as machining with
geometrically undefined tools
The Place of Machining Operations
• Machining operations are
capable of producing more
precise dimensions and
smooth surface finishes than
all other manufacturing
processes. They are performed
after other processes, which
create the general shape of
the parts. Machining then
provides the final geometry,
dimensions and finish.
Cutting Tools
Classification
1. Single-Point Tools – One dominant
cutting edge – Point is usually
rounded to form a nose radius –
Turning uses single point tools

2. Multiple Cutting Edge Tools – More

than one cutting edge – Motion
relative to work achieved by rotating –
Drilling and milling use rotating
multiple cutting edge tools
Cutting Conditions In Turning
ENR212- Lecture 8- Slide No. 11

Three dimensions of a Cutting Conditions in Turning

machining process: • Three dimensions of a machining process:

– Cutting speed v – primary motion
– Feed f – secondary motion

• Cutting speed v – primary – Depth of cut d – penetration of tool below original work
surface

motion
• Feed f – secondary motion
• Depth of cut d – penetration
of tool below original work
surface
Machine Tools
•A power-driven machine that performs a
machining operation, including grinding
• • Functions of machine tool :
•– Holds workpiece
•– Positions tool relative to work
•– Provides power at speed, feed, and depth that
have been set
•The traditional machine tools used to perform
turning, drilling, and milling are lathes, drill
presses and milling machines, respectively.
Orthoganal Cutting
Model
• The first diagram is the orthogonal cutting- the
cutting edge is straight and is set in a position
that is perpendicular to the direction of
primary motion This will allow us to deal with
stress and strains that act in a plane
OBLIQUE
CUTTING MODEL
• Oblique cutting – The cutting edge is set at an
angle. This is the case for three dimensional
stress and strains conditions.
CHIP
FORMATION • There are 3 commonly • Discontinuous chips comes
off as small chunks or
produced in cutting particles.
1. Discontinuous chips • It indicates :
A. Brittle work material
2. Continuous chips B. Small or negative rake
3. Continuous chips with angles
build up edge C. Coarse feeds and low
speeds
• A continuous chip looks like a
long ribbon with a smooth
shinning surface.
• It indicate
A. Ductile work material
B. Large positive rake angle
C. Fine feeds and high speeds
DIAGRAM OF CHIPS

A B C

A. Chip is discontinuous at low cutting velocity

B. Fors with a built up edge
C. Continuous with well developed secondary shear zone at high velocity
 • Discontinuous chips are • Three principle
CHIP generally desired due to: methods to produce
• Less dangerous to the favorable
CONTROL operator discontinuous chip
• Do not cause damage to • Proper selection of
workpiece and machine cutting condition
tool • Use of chip breaker
• Easy to recover from • Change in the work
work zone material properties
• Easy to handle and
disposed after machining
Cutting Fluid
• Cutting fluid (coolant) is any liquid or gas that is applied to the chip and/or
cutting tool to improve cutting performance. A very few cutting operations
are performed dry, i.e., without the application of cutting fluids. Generally, it
is essential that cutting fluids be applied to all machining operations.
• Main 3 function:
1. to remove heat in cutting: the effective cooling action of the
cutting fluid depends on the method of application, type of the cutting
fluid, the fluid flow rate and pressure.
2. to lubricate the chip-tool interface: cutting fluids penetrate the tool-chip
interface improving lubrication between the chip and tool and reducing the
friction forces and temperatures.
3. to wash away chips: this action is applicable to small, discontinuous chips
only. Special devices are subsequently needed to separate chips from cutting
fluids.
 Types of cutting
fluid
• Cutting oils
 Cutting oils are cutting fluids based on mineral or fatty oil mixtures.
Chemical additives like sulphur improve oil lubricant capabilities. Areas of
application depend on the properties of the particular oil but commonly,
cutting oils are used for heavy cutting operations on tough steels.
• Soluble oil
 The most common, cheap and effective form of cutting fluids consisting of
oil droplets suspended in water in a typical ratio water to oil 30:1.
Emulsifying agents are also added to promote stability of emulsion. For
heavy-duty work, extreme pressure additives are used. Oil emulsions are
typically used for aluminum and cooper alloys.
• Chemical fluids
 These cutting fluids consists of chemical diluted in water. They possess
good flushing and cooling abilities. Tend to form more stable emulsions
but may have harmful effects to the skin.
Roughing and
Finishing
•In production, several roughing cuts are usually
taken on the part, followed by one or two finishing
cuts
•• Roughing cuts - remove large amounts of material
from starting workpiece
• – Creates shape close to desired geometry, but
leaves some material for finish cutting – High feeds
and depths, low speeds
• • Finishing cuts - complete part geometry
•– Final dimensions, tolerances, and finish
• – Low feeds and depths, high cutting speeds
Surface finish
• The machining processes generate a wide
variety of surface textures. Surface texture
consists of the repetitive and/or random
deviations from the ideal smooth surface.
These deviations are
 Roughness – small finely spaced surface
irregularities (micro irregularities)
 Waviness – Surface irregularities of greater
spacing (macro irregularities)
 Lay – Predominant direction of surface
texture
Roughness control
• Factors influencing roughness in machining
are:
o Tool geometry
o Cutting condition
o Work material
 Non-traditional
processes: Water jet
cutting
Water jet cutting is a manufacturing process that
uses a high-pressure stream of water, often mixed
with abrasive particles, to cut through various
materials.

It's a versatile and precise method commonly used

in industries such as aerospace, automotive, and
construction.

Water jet cutting works by forcing a high-velocity

jet of water through a tiny nozzle at extremely high
pressure. Depending on the application, abrasive
particles like garnet may be added to the water
stream to enhance cutting efficiency.