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Science Technology
Orthogonal Cutting
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Machining processes
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Mechanics of cutting
Simple 2D orthogonal cutting can help explain the general mechanics of
metal removal
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Chip
Tool
Workpiece
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- rake angle;
- shear angle
- tangential force;
- feed force
- force acting along the shear plane
- normal force acting on the shear plane
- force acting on the rake face
- frictional force
cos
=
sin
sin
cos
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sin =
= sin
&
&
cos =
= cos
sin
=
cos
From mass (volume flow rate) conservation, chip thickness ratio chip length ratio
=
= =
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Velocity relations
/
=
= =
/
sin
= =
cos
=
8
sin
cos
cos
cos
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tan =
Small
angles
2 2 2 2
=
=
=
+
= cot + tan
1
1 1
cos
=
cos
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11
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= cos sin
sin
= sin + cos
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13
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14
cos
=
sin
sin
cos
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15
Tool
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Tool
= cos sin ;
= sin + cos ;
16
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= cos sin
= sin + cos
cos
cos
sin
cos
- shear angle?
- force acting along the shear plane?
- frictional force?
17
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= cos +
cos
cos
sin
Resultant cutting force can be now be expressed in terms of shear stress, friction and shear
angles, width of cut, and feed rate as follows:
=
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1
=
cos +
sin cos +
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1
=
cos +
sin cos +
Recalling the FCD
= cos =
cos
sin cos +
Nature always take the past of least resistance, so during cutting takes a value such that least
amount of energy is consumed, i.e. since , , , and and are given and do not change,
power consumed becomes:
=
19
sin cos +
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=
sin cos +
2 + =
20
4
2
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Force prediction
Shear angle using Merchants minimum energy principle
=
4
2
Force prediction
= cos =
cos
sin cos +
Power consumed
=
Shear angle prediction with these and other such models are not very accurate
But, they provide important relationships between tool geometry and shear
angle which is important for tool design, i.e. the rake angle must increase
without compromising strength of the cutting edge
Also important is the relationship between friction coeff. and shear angle, it
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Importantly, force and power consumed decrease with increase in shear angle
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sin
=
=
cos
Rearranging
= tan1
cos
1 sin
Obtaining ?
Non-uniform chip thickness after
machining makes measuring difficult
= =
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Contact mechanics between flank face and finished surface depends on tool wear,
23
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= + ;
= + ;
All cutting force expressions presented up until now were only for shearing, but in reality edge
forces also exist, hence edge forces must be subtracted from measured tangential and feed
forces before applying laws of orthogonal cutting mechanics
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sin
= cos ;
= sin ;
(b)
1
sin cos +
(a)
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cos
sin cos +
sin
sin cos +
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cos
sin cos +
sin
sin cos +
In metal cutting literature, we define tangential and feed force cutting force coefficients as
=
cos
sin cos +
sin
sin cos +
Cutting force coefficients are a function of shear stress, friction angle, shear angle tool
geometry, i.e. rake angle. Of these only know tool geometry beforehand. Moreover, shear
angle models are inaccurate, and friction too is less understood. Hence these are often
calibrated from experiments.
26
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Mechanistic modeling
= + ;
= + ;
cos
= bh
sin cos +
= bh
sin
sin cos +
= + ;
= + ;
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cos
sin cos +
sin
sin cos +
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Step 2
Setup tube
on a lathe
Step 3
Turning tool with zero inclination
angle, flat rake face, and no chip
breaker
Step 4
Select speeds most often used
in your application
Step 5
Measure cutting forces
using dynamometer
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Step 6
Repeat tests for a
range of feed rates
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Disadvantages:
Need to specially prepare tubes and tools
Need to conduct quite a many tests for complete characterization of
speeds, feeds and geometry
Not directly applicable to tools with proper geometry and chip breakers
used in many applications
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Test 4
Test 1
300
240
Ff
Ff
220
Ft
Ft
250
200
180
200
160
140
120
150
100
80
100
60
40
30
1000
2000
3000
4000
5000
6000
7000
8000
9000
50
1000
2000
3000
4000
5000
6000
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= + ;
= + ;
Prediction
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= 14;
= 13;
Units:
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