Orthogonal and Oblique cutting

(a) Orthogonal (b) Oblique

Orthogonal Cutting The cutting edge of the tool is perpendicular to the direction of cutting velocity. The cutting edge is wider than the workpiece width and extends beyond the work piece on either side. Also the width of the workpiece is much greater than the depth of cut. The chip generated flows on the rake face of the tool with chip velocity Dr. Ratnakar Das, KIIT University perpendicular to the cutting edge.

Oblique Cutting The cutting edge of the tool is inclined at an angle l with the normal to the cutting velocity vector. Angle l is also known as inclination angle. The ship generated flows on the rake face of the tool at an angle approximately equal to inclination angle with the normal to the cutting edge in the plane of the rake face The cutting edge extends beyond the width of the work piece on either side. The cutting forces act along all three directions.

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Pure orthogonal cutting

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The factors that affect the chip formation: The depth of cut to feed ratio Number of active and passive cutting edges The length of cutting edge to width of cut ratio The cutting speed The inclination angle The rake angle The depth of cut to diameter ratio The action of cutting fluid Based on these factors, the basic differences arise from Whether the cutting is orthogonal or oblique Whether the cutting is free or restricted Whether the chip is produced under plane strain conditions or not

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Causes of chip flow deviation

Ideal direction of chip flow in turning

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The chip flow may deviate form the orthogonal plane due to the following factors: Restricted cutting effect Tool nose radius Presence of inclination angle What are free and restricted cutting then?
Free cutting is characterized by the fact that the chip removal is caused by one straight cutting edge Restricted cutting is affected by either by one curvilinear cutting edge or simultaneous action of several active or passive cutting edges
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Restricted cutting effect (RCE)

It indicates that the chip flow may deviate even if in absence of the inclination angle. The angle of deviation() though small, depends upon cutting angle and depth of cut to feed ratio.
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Effect of tool nose radius

The value of principal cutting edge angle varies from zero over the curved portion of the principal cutting edge. This variation deviates the chip flow. Due to this variation, cutting edge angle is considered as average value. This variation in actual and average cutting edge angle is governed by the ratio of depth of cut to nose radius Dr. Ratnakar Das, KIIT University

Effect of inclination angle,

When it occurs? In absence of RCE and tool nose radius, the chip flow deviation is governed by the inclination angle

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Definition of effective rake The angle of inclination of the rake surface from R and is measured on that plane which is perpendicular to the reference plane and is taken in the direction of actual chip flow

In case of oblique cutting, which is practically more common, the actual direction of chip flow and the corresponding rake angle, i.e., effective rake should be used for more reasonably Dr. Ratnakar Das, KIIT University accurate analysis and assessment of cutting forces, friction and tool wear.

In contrary to simpler orthogonal cutting, oblique cutting causes the following effects on chip formation and mechanics of machining: Chip does not flow along the orthogonal plane;
Positive causes

Chip flow deviation away from the finished surface, which may result lesser further damage to the finished surface but more inconvenience to the operator reduction of mechanical strength of the tool tip increase in temperature at the tool tip more vibration in turning slender rods due to increase in transverse force

Dr. Ratnakar Das, KIIT University