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and
Digital Manufacturing
(For B.E. Mechanical Engineering Students)
ISBN:978-93-84893-72-9
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ISBN : 978-93-84893-72-9
and
Syllabus S.1
Contents
Chapter 1
Theory of Metal Cutting
1.1 Introduction to Metal Cutting . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.2 Cutting Tool Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.3 Parts and Nomenclature of Single Point Cutting Tool . . . 1.3
1.4 Tool Signature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
1.4.1 Influence of Tool angles in machining . . . . . . . . 1.8
1.5 Methods of Metal Cutting Processes . . . . . . . . . . . . . . . . . 1.10
1.5.1 Differences between orthogonal and oblique cutting. 1.11
1.6 Mechanism of Metal Removal Processes . . . . . . . . . . . . . . 1.12
1.6.1 Classification of Metal Removal Processes . . . . . . 1.12
1.6.2 Chip forming Processes . . . . . . . . . . . . . . . . 1.12
1.6.3 Turning, Boring and other Lathe Operations . . . . 1.13
1.6.3.1 Machining parameters and related terms in
turning operation . . . . . . . . . . . . . . . . . . 1.15
1.6.4 Shaping, Planing and Slotting . . . . . . . . . . . . 1.18
1.6.4.1 Machining Parameters in Shaping, Planing . . . 1.20
1.6.5 Drilling and Reaming . . . . . . . . . . . . . . . . . 1.21
1.6.5.1 Machining Parameters for Drilling . . . . . . . . . 1.22
1.6.6 Milling . . . . . . . . . . . . . . . . . . . . . . . . . 1.22
1.6.6.1 Machining Parameters in Milling . . . . . . . . . 1.25
1.6.7 Broaching . . . . . . . . . . . . . . . . . . . . . . . . 1.26
1.6.8 Thread Cutting . . . . . . . . . . . . . . . . . . . . . 1.26
1.6.8.1 Machining Parameters in thread cutting . . . . . 1.27
1.6.9 Grinding . . . . . . . . . . . . . . . . . . . . . . . . 1.28
1.6.10 Honing and Lapping . . . . . . . . . . . . . . . . . 1.29
1.6.11 Gear Cutting . . . . . . . . . . . . . . . . . . . . . 1.29
1.7 Primary and Secondary Deformation Shear Zones . . . . . 1.30
1.8 Mechanism of Chip Formation . . . . . . . . . . . . . . . . . . . . . . 1.32
1.8.1 Types of Chips . . . . . . . . . . . . . . . . . . . . . 1.32
1.8.1.1 Variables affecting type of chip . . . . . . . . . . 1.33
C.4 Machine Tools and Digital Manufacturing
Chapter 4
Milling Machine
4.1 Milling Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.2 Milling Machines and Types . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.3 Principal Parts of Milling Machine . . . . . . . . . . . . . . . . . . . 4.9
4.4 Size and Specification of Milling Machine . . . . . . . . . . . . 4.10
C.10 Machine Tools and Digital Manufacturing
Chapter - 5
Grinding Machines
5.1 Grinding Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.2 Principle Operations of Grinding . . . . . . . . . . . . . . . . . . . . . 5.2
5.3 Classification of Grinding Machines and Processes . . . . . . 5.2
5.3.1 Rough grinders . . . . . . . . . . . . . . . . . . . . . 5.4
5.3.2 Precision grinding machines . . . . . . . . . . . . . 5.7
5.3.3 Cylindrical grinding (centre type) machines . . . . . 5.7
5.3.3.1 Plain centre type grinder . . . . . . . . . . . . . . . 5.9
5.3.3.2 Universal centre type grinder . . . . . . . . . . . 5.11
5.3.3.3 Plunge-centre type grinding machine . . . . . . . 5.13
5.3.4 Centre-less type grinding machines . . . . . . . . . . 5.13
5.3.4.1 Principle of working . . . . . . . . . . . . . . . . . 5.14
5.3.4.2 Methods of centreless grinding . . . . . . . . . . . 5.15
5.3.4.3 Advantages of centreless grinding over
cylindrical grinding . . . . . . . . . . . . . . . . . . 5.17
5.3.5 Internal Grinders . . . . . . . . . . . . . . . . . . . . 5.17
5.3.6 Surface grinding machines . . . . . . . . . . . . . . 5.21
5.3.7 Tool and cutter grinder . . . . . . . . . . . . . . . . 5.24
Contents C.11
Se tting
C hip Too l An gle
Sh ea r Plane
II
A
I
W ork C le arance
B A ngle( )
Sh ea r
III
D epth of A ngle( )
C ut
Fig. 1.1 (a) Po sition of too l in relation to w o rk.
1.2 Machine Tools and Digital Manufacturing
cutting edge, good tool finish, good tool geometry, using cutting
fluid etc.
In front of cutting tool point, generally no crack is observed. Due
to strain hardening, the hardness of metal in chip, the built up
edge and near the finished surface is usually greater than that for
the metal.
Sometimes a built up edge is formed at the tip of the tool and it
significantly alters the cutting process. It deteriorates the surface
finish and rate of tool wear is increased.
Shank : Shank is the main body of the tool at one end of which the
cutting portion is formed.
Neck : The portion which is reduced in section to form necessary
cutting edges and angles is called the neck.
Face : Face of the tool is the surface across which the chips travel
as they are formed and is visible to the operator when looking
down at the top from above.
Base : Base is the surface on which the tool rests.
1.4 Machine Tools and Digital Manufacturing
E n d C uttin g E d ge A n g le
N o se A n gle
(a) N e ck S h an k
S ide
R a ke w id th
A n gle Fa ce B a ck R ake A ng le
P o in t
Flan k
H e ig ht L ip
A n gle
H e el
(b) B a se
S ide
E n d R elie f C le a ran ce
R e lie f (c)
A ng le A ng le
A ng le
to 22.
The side rack angle of a tool determines the
(b )
tool thickness behind the cutting edge. Fig. 1.2 S ide
R e lie f
(ii) Back rake angle: Back rake angle is the A n g le
angle between the face of the tool and a line
parallel to the base of the shank in a plane parallel to the centre line of the
point (or parallel to the side cutting edge) and at right angles to the base.
If the inclination of face
Fa ce
backwards is downwards, the back P o in t
B a ck R ake A ng le
negative. A n gle
the flank immediately below the point and a line drawn from the point
perpendicular to the base.
Excessive relief angle reduces the strength of tool, therefore, it should
not be too large. Generally its value varies from 6 to 10
(iv) Side relief angle: Side relief angle is provided on the tool to provide
clearance between its flank and the workpiece surface. It is the angle between
the surface of the flank immediately below the point and a plane at right
angles to the centre line of the point of the tool. This angle must be large
enough for turning operations to allow for feed helix angle on the shoulder
of workpiece.
(v) End cutting edge angle: It
E n d C uttin g E d ge A n gle
provides clearance between the tool
cutting edge and workpiece, and the N o se A n gle
side cutting edge angle is
responsible for turning the chip S ide cuttin g
C u tting
away from the finished surface. Side E d ge Fa ce
E d ge A n gle
the side of the tool and side of the Fig. 1.2 (a)
(ix) Lip Angle: It is the angle between the tool face and the ground end
surface of flank. It is usually between 60 and 80
Tool Signature 8 16 7 7 8 16 6 mm
Back rake Angle
Side rake Angle
End relief Angle
Side relief Angle
End Cutting edge Angle
Side cutting edge Angle
Nose radius
1.8 Machine Tools and Digital Manufacturing
R
R
T T T
A tool has positive rake when the face of tool slopes away from the
cutting edges and slants towards the back or side of the tool.
Theory of Metal Cutting 1.9
A tool has zero rake when the face of tool has no slope and in the
same plane or parallel to upper surface of shank. Turning brass usually have
zero rake tools. Zero rake increases strength of tool and prevents cutting edge
from digging into the work.
A tool has negative rake when the face of the tool slopes away from
the cutting edge and slants upwards towards the back or side of tool. It is
used in turning metal with cemented carbide tipped tool in mass production.
2. Clearance angle
Clearance angle prevents the flank from rubbing against the surface of
work allowing only cutting edge to come in contact with the workpiece.
Front clearance angle prevents front flank of tool from rubbing work
piece. It is large for large work diameter.
Side clearance angle prevents the side of the tool from rubbing work
when longitudinal feed is given. Larger feed requires large side clearance
angle.
3. Nose radius
Nose radius clears feed marks caused by previous shearing action.
It increases strength of cutting edge and hence increase tool life.
High heat dissipation.
6. Lip Angle
Lip angle influences the strength of cutting edge. Lip angle directly
depends upon rake clearance angle. Large lip angle helps in machining harder
metals, giving high depth of cut, increases tool life and improves dissipation
of heat.
a
b
nc
ip
Ch
o c
o
i
c
v
rk
d
wo
v
S.
Orthogonal Cutting Oblique Cutting
No.
1. The cutting edge of the tool The cutting edge of the tool
remains at 90 to the direction of remains inclined at an acute angle
feed (of the tool or the work) to direction of feed.
2. The chip flows in a direction The chip flow is not normal but
normal to the cutting edge of the at an angle to the normal to
tool. the cutting edge.
3. The cutting edge clears the width The cutting edge may or may not
of the work piece on either ends. clear the width of the workpiece.
4. Only two components of cutting Three components of cutting force
force which are perpendicular to perpendicular to each other acts on
each other are acting on tool. the tool.
5. Maximum chip thickness occurs at Maximum chip thickness may not
the middle. occur at middle.,
1.12 Machine Tools and Digital Manufacturing
S.
Orthogonal Cutting Oblique Cutting
No.
6. The shear force acts on a smaller The shear force acts on a large
area, so shear force per unit area area, hence shear force per unit
is more. area is smaller.
7. Tool life is smaller than that in Tool life is higher than orthogonal
oblique cutting. cutting.
8. The cutting edge is bigger than the The cutting edge is smaller than
width of cut. the width of cut.
C h uck C h uck
C h uck
W ork
W ork W ork
Fig 1.6 Plain turn ing Fig 1.7 Step turning Fig 1.8 Facing
Facing: When the feed motion of the tool is axial i.e parallel to the work
piece axis, a cylindrical surface is generated. If on the other hand, feed motion
is radial (normal to the axis of rotation), an end face or shoulder is produced.
This operation is called facing as shown in Fig. 1.8.
Boring: Boring is a machining operation for generating internal surface of
revolution i.e., it is an operation of enlarging of a hole already made in
workpiece with the help of a single point tool called boring tool. Boring tool
is held in the tool post and fed into the work by hand or power by movement
of carriage. Boring is shown in Fig. 1.9
1.14 Machine Tools and Digital Manufacturing
C h uck C h uck
W ork W ork
B o rin g to ol D rill
C h uck
C h uck
W ork
W ork
R e am e r
Too l
into the rotating work piece upto the desired depth at right angles to the
centre line of the work piece.
Threading: It is an operation of cutting helical grooves (threads) on the
external cylindrical surface of workpiece as shown in Fig. 1.13. The work is
held in a chuck or between centers and the threading tool (V-tool) is fed
longitudinally to the rotating workpiece. The longitudinal feed is equal to the
pitch of the thread to be cut.
W ork
W ork
D irection of ro tatio n
W ork pie ce
DN
V in m/min
1000
Area of Uncut Chip: It is the cross sectional area Ac of the layer of the
work being machined.
Area of Uncut chip Ac f d.
Metal removal rate (Rw: It is the volume of material being removed per
unit time from the work piece.
Rw 1000 f d V in mm3/min
Here, f, d are in mm, V is in m/min
Machining time: If L is the length of workpiece to be turned, then the time
of cutting Tc per pass is given by
L la
The Machining Time Tm
f N
Problem 1.1 Evaluate the machining time for turning of a 100 mm diameter
rod to 92 mm diameter over a length of 60 mm at a spindle speed of 500
RPM. The maximum depth of cut is limited to 3 mm and the feed f is 0.5
mm per rev. The side cutting edge angle of the tool is 30. Approach
allowance 5 mm. Also calculate cutting speed for each pass.
Given: Initial diameter Di 100 mm, Final diameter Df 92 mm, Length
L 60 mm, Speed N 500 RPM, d 3 mm,
Solution
Total diameter to be reduced Di Df 100 92 8 mm
Tool m otio n
Tool
W ork P ie ce
the work which is supported on the table reciprocates past the stationary
cutting tool and the feed is supplied by the lateral movement of the tool,
whereas in shaping the tool which is mounted upon the ram reciprocates and
the feed is given by the crosswise movement of the table. Planing operations
are carried on machine tool called “planer”.
Slotting operation falls into the category of shaping and planing. The major
difference between a slotting and shaping is that in a slotting, the ram holding
the tool reciprocates in a vertical axis, whereas in shaping the ram holding
the tool reciprocates in a horizontal axis. A vertical shaper and slotter are
almost similar to each other as regards their construction, operation and use.
Slotting operation is used for cutting grooves, keyways, slots of various
shapes, for cutting internal and external gears etc.
N L 1
Cutting Speed V in m/min
1000
Depth of Cut d: Depth of cut is equal to the normal distance between
the unmachined and machined surface measured along a normal to the
machined surface.
Nominal feed rate f is equal to the movement given to the workpiece in
a shaper (or to the tool in planer) in a direction normal to other cutting
velocity direction.
Bw
Machining time Tm For Shaping
fN
Bw ls Bw
Tm 1 t .
f Vc fs r
s
D rill
W ork p ie ce
f
t
b b
D2 f N
Metal removal rate Rw in mm3/min
4
L
Machining time Tm
fN
where L Length of hole.
1.6.6 Milling
Milling is a machining process in which flat as well as curved surfaces
are produced by rotating multi-edges cutting tools called milling cutters and
the work is fed past it. The work piece is rigidly mounted on the machine
Theory of Metal Cutting 1.23
table and the cutter is on the spindle or arbor. The work is fed slowly past
the cutter while the cutter revolves at fairly high speed. The main milling
operations are
Slab milling, Form milling,
Face milling, Angular milling etc.
Slot milling,
These may be classified into two types i.e peripheral milling and face
milling. The operations are shown in Fig. 1.19.
C u tte r
W ork p ie ce
(a )S la b m illin g (b )P ro file m illin g
C lim b m illing
C u tte r
W ork
Table
Stop
Fig. 1.20. M illing O peration (b ) D o w n m illin g
(b) Climb or down milling: In this method, the work is fed in the
direction of rotation of cutter. Fig 1.20 (b)
C onvention al m illing
C utter
W ork
Table
Stop
Fig 1.20 (c) shows that the chips produced are not uniform in cross
section. In up milling, each tooth starts with a minimum thickness and ends
with maximum thickness (of the chip). In down milling, the reverse happens
i.e. each tooth starts with the maximum thickness and ends up with minimum.
Total volume of the chip for a cut by a tooth is same in both the cases.
Theory of Metal Cutting 1.25
t- de pth o f cu t
DN
Cutting Speed V in m/min
1000
In slab milling, the work piece is fixed on the machine table and feed
motion is given by table which is expressed in mm/min. If F is table feed
in mm/min and f is feed per tooth of cutter, then.
F
f mm/rev/tooth
nc N
C u tte r C u tte r
W ork p ie ce
a2 a1
A
lw A a1 a2
Machining Time Tm
F
l2, Length of workpiece in the feed direction.
A[D d] d
1.6.7 Broaching
Broaching is a machining operation in which a multitooth cutter called
a broach is pushed or pulled over the surface to be machined while keeping
a desired interference between broach teeth and the surface. Generally it is a
single stroke operation. Broaching is generally limited to the removal of 6
mm of stock or less. A continuous Broaching Operation is shown in Fig.1.22.
C o m p o ne nt
U n lo ad in g
L oa ding
S u pp ort
Fixture s
Tool
Lea d screw
L C arria ge
Fig 1.23
1.18 A Schem atic View of Thread Cutting on Lathe
1.6.9 Grinding
Grinding is a machining operation in which a multi-edged rotating
abrasive tool called grinding wheel removes excess material from the work
piece. Grinding is finishing operation removing material usually 0.25 to 0.5
mm in most operations and accuracy in dimensions is in order of 0.000025
mm. Typical grinding operations are shown in Fig. 1.24.
Grinding operations are broadly classified as rough or non precision
grinding and precision grinding.
Theory of Metal Cutting 1.29
........
..................
.. ......
.................
... ..
W ork Seconda ry
deform ation zone
VC Tool
The heat generated at the work tool interface occurs when the cutting
tool is not sharp. Usually the heat generated at this source is small and hence
could be neglected.
Theory of Metal Cutting 1.31
100
t
w
% of total hea d gene rated
75
50
C
25
0
10 20 30 40 50 60 70 80 90
C u tting feed m /m in
Ps Pm Pf
Heat is removed from the three zones by the workpiece, chip and the
tool. The relative amount of heat transformed to chip, workpiece and tool at
different cutting speeds is shown in Fig. 1.26. This diagram is for machining
of steel with a single point tool having cemented carbide tip. As the cutting
speed increases, more heat is carried away by the chip and less heat is
transferred to the workpiece and the tool. High speed machining is, therefore
advantageous to the tool life.
The tool rate of heat generation,
Pw c w t
C hip
Tool
W ork piece
deformation as shown in Fig. 1.27 (a). Both these zones and the sliding of
chip on rake face produce heat.
The extent of primary zone deformation depend upon.
(i) Cutting speed (ii) Rake angle of tool (iii) Friction on rake face
(iv) Work material characteristics.
With large rake angle tools, the chip formation is gradual and material
suffers less overall deformation. Cutting forces are also low. With small or
negative rake angle tools, the material suffers more severe deformation with
large cutting forces.
At high cutting speed, the thickness of the primary zone of deformation
shrinks i.e it becomes narrower.
chip and tool interface, a portion of chip gets welded on the tool face forming
the embryo of built up edge (BUE). The strain hardened chip is so hard that
now it becomes part of the cutting edge and starts cutting the material. Since
this built up edge is irregular in shape, the surface produced becomes rough.
As the machining continues, more and more chip material gets welded on
the embryo built up edge, this increases its size and ultimately, it becomes
unstable and gets sheared off. This cycle is repeated. During the unstable
stage, some fragments of the built up edge are carried along the under surface
of chip while some escape along the flank thus worsening the surface finish
of the machined surface. [Fig. 1.27(b)]
B U E = B uilt U p E dg e
B u ilt u p e d ge
Fra g em en ts o f B U E
W ork p ie ce
Too l
C h ip
In itiation o f B U E
W ork p ie ce
(a) I n itiatio n o f B U E
Too l
C h ip
G ro w th of B U E
W ork p ie ce
(b) G row th of B U E
C h ip Too l
Fra g m e nts of
BU E
W ork p ie ce
(c) B reaking of B U E
C h ip s
Too l
W ork p ie ce
of the cutting tool, the crack travels and a small lump of material starts
moving up the rake face as shown in Fig. 1.29.
In itial C h ip
d efo rm atio n C ra ck seg m en t
Fo rm atio n
The force and constraints of motion acting on the lump make the crack
propagate towards the surface, and thus a small fragment of chip gets
detached. As the tool moves further, this sequence is repeated.
Following are conditions at which discontinuous chips are formed
Use of brittle material
Smaller negative rake angle
Large chip thickness i.e. large depth of cut and high feed rate.
Low cutting speeds
Dry cutting i.e. cutting without use of cutting fluid.
1.38 Machine Tools and Digital Manufacturing
C h ip
B tC Too l
VS Vt
E
t
VC
G - A
B
Vt
C
E
VS
D A
VC
sin
So, Vt Vc
cos ...(1.1)
Similarly, from right angle triangle AED, AEB we have
AE Vc cos ; AE Vs cos
Vc cos Vs cos
cos
So, Vs Vc
cos ...(1.2)
Theory of Metal Cutting 1.41
t
Chip thickness ratio r
tc
t tc
AB , AB
sin cos
dividing the above two equations we have
AB t/sin
AB tc/cos
t sin ...r t
i.e. r
tc cos tc
t sin
r
tc cos cos sin sin
. .
. cos cos cos sin sin
r cos cos sin sin sin
r cos cos sin sin
1
sin
cos
r r sin 1
tan
r cos
1 r sin
tan
. . r cos
. tan
1 r sin
1.42 Machine Tools and Digital Manufacturing
r cos
(or) Shear Angle tan 1
1 r sin ...(1.3)
1
(Here the term is termed as chip reduction coefficient or chip
r
compression factor and is denoted by K)
The cutting ratio or chip thickness ratio is always less than unity and
can be evaluated by measuring chip thickness and depth of cut. But it is
difficult to measure chip thickness precisely due to roughness on back surface
of chip.
The chip reduction coefficient can also be estimated in a different
manner by measuring the length of the chip (lc
t l tc lc
t lc
tc l
t t lc
We know r so, r [chip thickness ratio or cutting ratio]
tc tc l
Also density of metal can be used to find the chip reduction coefficient
tb
r
m ...(1.5)
where m is Weight per unit length of metal.
Theory of Metal Cutting 1.43
Fx
a
Fd
c
b Fy
Feed
Fr
Fz
Fc
R
(i) Feed Force Fd: It is horizontal component of the cutting force, acting
in the direction of feed of the tool. It is acting tangent to the generated
surface.
(ii) Thrust force Fr: It is reaction force between the tool and the work
piece acting in radial direction perpendicular to feed direction.
(iii) Main cutting force Fc: It is the vertical component of the cutting
force acting in vertical direction.
The resultant force R F2d F2r F2c
C hip Tool
F
Fs N Fd
Feed Fa
Fc
W ork
Fc pie ce Feed
Fn Fd
(a)
Fig. 1.33. O rtho go nal Turn ing .
The two components of forces Fd, Fc and forces acting on chip are
shown in Fig. 1.33(a).
As the cutting tool moves along the feed direction, the metal gets
plastically deformed along the shear plane and the chip moves along the rake
surface of tool and due to roughness of chip, frictional Force F is acting
on the tool.
Following are the forces developed.
R
F2n F2s ; R
F2 N2
Both R and R are equal in magnitude and opposite in direction and
are collinear since chip is in equilibrium.
Theory of Metal Cutting 1.45
C hip
R·
Fs
Fn
Fig. 1.34. Free bod y
diag ram
shear angle
angle of friction ;
Forces Fd and Fc can be measured by dynamometer
Once the Fd, Fc, and are known, all the other components of forces
acting on the chip can be determined by the geometry shown in Fig 1.35.
We can draw the following figures from Fig 1.35 and find relations.
From the Fig 1.36(a) we have from the geometry
d
C
e
B
Fs
c o
Fc Fc
D A f
-
Fd R
Fn
Fd F
R
b
E
(a) N (b)
a
Fig. 1.36. G eom etry of Forces
Fs AB AC BC ; Fc AD ; Fn BE
Fs AB Fc cos Fd sin
Fc cos
or Fs
cos ...(1.9)
From Fig 1.36(b) we have.
N ab oe od de
N Fc cos Fd sin
Since F ao be
ef fb cd fb
FN
Coefficient of friction
F Fc sin Fd cos
N Fc cos Fd sin
...(1.11)
dividing the numerator and denominator by cos we get
Fc tan Fd
Coefficient of friction
Fc Fd tan ...(1.12)
bt
Fs s
sin ...(1.13)
Substituting 1.13 in 1.8 we get
Theory of Metal Cutting 1.49
bt cos
Fc s
sin cos ...(1.14)
For maximum Fc, we have
d Fc
0
d
d Fc d s b t cos
0
d d sin cos
d 1 0
s b t cos
d sin cos
d Fc
s b t cos
d
or Shear Angle
4 2 2 ...(1.15)
The above relationship is based on Earnest Merchant Theory and also
called as “Modified Merchant Theory”, which makes the following
conclusions.
1. The stress is maximum at the shear plane and it remains constant.
2. The shear takes place in a direction in which the energy required
for shearing is minimum.
1.50 Machine Tools and Digital Manufacturing
s 0 K n
...(1.16)
bt cos
Fc 0 K n
sin cos
For maximum Fc, we have
d Fc
0, we get cos 2 K
d
or 2 cos 1 K
cos 1 K
Shear Angle
2 2 2 ...(1.17)
Ff Frictional force,
Fc Vc Fs Vs Ff V ...(1.20)
Fc Vc
Also cutting Power in Pc kW
60 75 1.36 ...(1.21)
Here Fc Vc is workdone in kgm/min.
Pc 6120
Or Force of Cutting Fc
Vc ...(1.22)
Here Fc is in kg, Vc in m/min, Pc in kW
Fs
We have Shear Stress s where Fs Shear force
As
1.52 Machine Tools and Digital Manufacturing
w.t
We know that As
sin
Fs sin
s
wt ...(1.25)
From the equation 1.6 we have
Fs Fc cos Fd sin
x
s
Tool
s
x
9 0-
x -
A B C D
s
Fig.1.37. Shear Strain.
Theory of Metal Cutting 1.53
s AC AB BC
We know that Strain e
x x x
AB BC
e
x x
x tan 90 x tan
x x
e tan tan 90 ...(1.27)
e tan cot
sin cos
cos sin
sin sin cos cos
e
sin cos
sin [sin cos cos sin ] cos [cos cos sin sin ]
e
sin cos
. .
. sin A B sin A cos B cos A sin B
cos A B cos A cos B sin A sin B
sin2 cos sin cos sin cos2 cos cos sin sin
e
sin cos
E Fc Vc Fc
Em
Vc w t Vc w t w t
... (1.31)
The total energy required per unit volume of metal removed is
ETot Es Ef Ea Em
s Vs F
Es and Ef
Vc sin w tc
... (1.32)
Practically all the energy required in metal cutting is consumed in the
plastic deformation on the shear plane and the friction between chip and tool.
due to transfer of atoms of hard alloy constituents of tool material into work
or chip materials resulting in heating of tool.
A wornout tool will have following effects
(i) Poor surface finish dimensional tolerence on work piece.
(ii) Increase in cutting force and thus increase in power consumption.
(iii) Increase in temperature and vibration.
Therefore tools must have high wear resistance.
(iii) Toughness
Toughness is the ability of a material to absorb deformation energy
before fracture. Tougher the material, higher the ability of material to absorb
impact loads and intermittent cuts. It is however observed from experience
that materials which are wear resistant and have high hot hardness are also
more brittle and therefore less tough.
(v) Friction
There should be low friction between the tool and workpiece since the
friction generates heat. The coefficient of friction between the tool and work
piece should be as low as possible.
(i) Carbon Steels : 0.8 to 1.3% C, 0.1 to 0.4% Mn, 0.1to 0.4%
Si
(ii) Carbon-Vanadium : 0.8 to 1.3% C, 0.1 to 0.4% Mn, 0.1 to 0.4%
Steels Si, 0.15-0.25% V
(iii) Carbon-Chromium : 0.8 to 1.3% C, 0.1 to 0.4% Mn, 0.1 to 0.4%
Steels Si, 0.40-0.60% Cr
Characteristics of HSS
High Tungsten HSS is the best of the above three for all purpose
tool steels.
Tungsten and Molybdenum increase the hot hardness.
Vanadium iron Carbide tools are very hard constituents of HSS
and imparts high wear resistance to tool at all temperatures.
To increase the cutting efficiency, 2 to 5% of Cobalt is added.
One of the composition 2% W, 4% Cr, 2% V, 12% Cobalt are
called Super high Speed Steels. Because of heavy cost, it is used
for heavy cut operations only.
HSS hot hardness is quite high so it retains the cutting ability upto
600C at 40 m/min.
HSS has high wear resistance and good hardenability.
Uses: HSS is used in Drill, Broaches, Reamers, Milling Cutters,
Taps, Lathe Cutting Tools, Gear hobs etc.
Characteristics of Stellites
Cast alloys are not hard at room temperature but becomes very
hard above 1000F (hardness more than HSS)
Cast alloys are very brittle hence not widely used.
Cast alloys have less toughness but more wear resistance than HSS
and allow cutting speed thrice than that of HSS.
Uses: Used in manufacture of Valve seats, Push rod sheets and
Erosion shield of steam turbine etc.
Advantages
Very high cutting speed so low machining time.
High tool life with large depth of cuts.
Low wear rate and hence high dimensional accuracy with high
surface finish.
Low cost of production.
Disadvantages
High initial cost-40 to 200% more than carbide tools.
High rigidity of machine tools is required.
More power required since high speed and feed rate.
Tools are brittle so proper tool geometry, holding devices are to
be used.
Application
Turning, boring and facing at high speeds, used for finishing
operation on non-ferrous and ferrous metals, machining of casting
and hard steels.
Cermets are ceramic metal combinations of Iron, Chromium,
Titanium and other metals, added to aluminium oxide and boron
carbide. The brittleness of the ceramic tools is considerably
reduced.
Characteristics of diamond
They are very hard, hence very brittle.
They are abrasion resistant with low coefficient of friction and low
thermal coefficient of expansion.
They burn to Co2 at 800C
Theory of Metal Cutting 1.63
Advantages
Very high production rate with close tolerance, high surface finish.
Small depth of cut can be given (0.215 micron).
Cost of grinding is reduced.
Chances of built up edge formation is nil.
Disadvantages
Very high cost.
Interrupted cut machining is not possible.
Machine tool should have high rigidity.
Cannot be used for machining beyond 800C.
Exclusively used for shallow cuts.
Applications
Used for machining non metals like rubber, ceramic, graphite and
plastic.
Used for machining precious metals like Platinum, Gold and Silver,
Soft metals like Copper, Brass, Zinc alloys.
C ra te r w e ar C ra te r w id th
Flan k w ea r Flan k w ea r
h eigh t
(a)
C ra te r w e ar
A B C -O rig in al
B B· B ·· B ··· C cross-se ctio n
(b)
Fig. 1.38. Too l W ear
Theory of Metal Cutting 1.65
C h ip m otion
S h ea r stre ss d u e
to chip
C h ip
S h ea rin g of
a rid ge
M ach in ed Too l
surface
S tee l c h ip
C
.
C h ip
HSS
H S S Too l
Too l
Too l p article
C h ip w e ld ed to chip
W eld
W eld
Too l
C h ip
Too l
H ard particle
C hip in chip& m achined surfa ce
Tool
C hip
M achined surface
Tool
The softer metal sliding over the surface of the harder metal may
contain appreciable concentrations of hard particles (Eg). Casting may have
sand particles. Under such condition, hard particles act as small cutting edges
like those of a grinding wheel on the surface of a hard metal which in due
course, is wornout through abrasion (Fig. 1.42). Also the particles of the hard
tool metal, which intermittently get torn out from its surface are dragged
along the tool surface or rolled over. These particles plough grooves into the
surface of the hard tool metal.
Tension C h ip Flow
Fo rce by chip
Tool
C o m pre ssio n
C h ip
Tool
Asperities are formed when two surface slides in contact with each
other under pressure. These asperities interlocks with each other. Due to
friction, compressive stress is developed on one side of asperity and tensile
stress on the other side (Fig 1.43). After the asperities of a given pair has
moved over or through each other, the above stresses are relieved. New pair
of asperities are soon formed and the stress cycle is repeated. Thus the
Theory of Metal Cutting 1.69
material of the hard metal near the surface undergoes cyclic stresses. This
phenomenon causes surface cracks and ultimately crumbling of hard metal.
The variable thermal stresses due to high temperature also contribute to fatigue
wear.
Flank Wear
(Refer Fig 1.38)
The wear at the side and end of flank of tool is called Flank wear.
Flank wear is caused by the rubbing action of the machined surface. The
worn out region is called wear land. Wear land is not of uniform width. It
is widest at a point farthest from the nose. When diffusion becomes
predominant wear mode on the flank, a critical wear land is formed and
accelerating wear rate takes place and then Rapid wear. It is advisable to
1.70 Machine Tools and Digital Manufacturing
C ra te r w e ar C ra te r w id th
Flan k w ea r Flan k w ea r
h eigh t
(a)
C ra te r w e ar
A B C -O rig in al
B B· B ·· B ··· C cross-se ctio n
(b)
Fig. 1.38. Too l W ear
R a pid w e ar
C
W id th of fla nk w e ar
O C T
Tim e
change the tool well before the on-set of the rapid wear in order to avoid
catastrophic tool failure. A typical wear curve for cutting is shown in Fig.1.44.
Crater Wear
Crater Wear occurs on the rake face of tool in the form of a pit called
crater. It is formed at a distance from the cutting edge. It is a temperature
dependent phenomenon caused by diffusion, adhesion etc. Fig 1.45 shows the
radius of curvature Rc, depth of crater KT, width of crater KB KM and the
distance of the start of the crater from the tool tip KM change with time. The
KM
RC
KT
A
KB
(a)
KB
RC
Va lu e o f C ha ractristic
KT
A
Tim e
(b)
crater significantly reduces the strength of the tool and may lead to total
failure.
In equation if T 1 then V C
Here the constant C can be physically interpreted as the cutting speed
for which the tool life is one minute.
In Taylor’s equation the tool life equation becomes straight line on
log-log scale as shown in Fig. 1.46 i.e log V n log T log C ...(1.34)
Theory of Metal Cutting 1.75
C uttin g sp ee d V (m /m in )
L og V + n L o g T
= Lo g C
Lo g V
Too l life T (m in ) L og T
Fig.1.46. Tool life V s C u ttin g speed
Id
speed for different tool ct
ea
C a rb oo
l
1 50 id e to l
materials. The tool life is ol
30
(iv) Effect of work material 1 2 3 5 10 20 30 5 0 1 00
hardness and microstructure Too l life,T, m in
A general emphirical Fig. 1.47 Effect To ol material
relationship between the Cutting Sp eed o n To ol life
T n K
For the tool with 90 cutting edge angle (orthogonal cutting), the
cutting edge is impact loaded over a small area and hence the
cutting force is very high there by reduces the life of tool.
For the tool with less cutting edge angle (oblique cutting) the tool
experiences cutting force gradually and over a larger area and
hence tool is safer and has more life.
damping is more and vibration is less and less chatter and more life. Chatter
causes fatigue or catastrophic failure of tool.
DL
Where CM Machining cost C1
1000 VS
Where C1 Direct labor cost Over head cost in Rs/min
Theory of Metal Cutting 1.79
1 C1 T1 C2
Topt 1
n C1
Wher e C2 Tool cost per grind
1.11.4 Machinability
The term machinability is used to refer to the ease with which a given
workpiece material can be machined under a given set of cutting conditions.
It is of considerable economic importance for a production engineer to know
in advance the machinability of a work material, so that its processing can
be efficiently planned.
L ay
In clusio n
(a )
A M a gn ified B low ho le
W a vine ss sp acin g
B W a vine ss he ig ht
(b)
B M a gn ified P e aks
Valle ys M ea n line
C u t o ff le ng th
(c )
Fig. 1.48. Elem en ts of S urface Texture
Theory of Metal Cutting 1.81
of roughness, waviness and lay. Microstructure describes the depth and nature
of the altered material zone just below the surface.
Surface finish (or surface texture) refers to the following properties of
a machined surface as shown in Fig. 1.48.
Roughness: Roughness consists of relatively close-spaced or fine surface
irregularities, mainly in the form of feed marks left by cutting tool on the
machined surface. The mean height or depth is measured over a 1 mm cut
off length or roughness sampling length.
Lay: Lay denotes the predominate direction of the surface irregularities. The
lay is usually specified with respect to an edge called the reference edge of
workpiece.
Surface flaws: These are random spaced irregularities i.e those which occur
at some particular location on the surface or at widely varying intervals. Flaws
could be due to inherent defects such as inclusions, cracks, blow-holes etc.
Lp
y hp
Lm h m ax
Lv
L
1
hp
L ydx
0
b
c
a
e d
o o
60 60
(iv) Cutting fluid should have low viscosity so that chip and dirt easily
settles.
(v) Cutting fluid should not be toxic in nature.
(vi) Cutting fluid should have high chemical stability such that it can
be used for longer time.
(vii) Cutting fluid should have high flash point
(viii) It should not be harmful to worker or operator
(ix) It should be non flammable
(x) It should not produce smoke or foam easily
(xi) It should not produce bad smell
(xii) It should be of low cost.
(i) Mineral oils (ii) Fatty oils (iii) Combination of mineral and fatty
oils.
These oil have good lubricating properties but poor heat absorption
quality and are used for low cutting speeds.
(iii) Oil with additives: The beneficial effects of mineral oils can be
improved with the help of additives which are generally compounds of sulphur
or chlorine. Addition of sulphur compounds reduces chances of chip welding
on tool rake face.
Theory of Metal Cutting 1.87
Additive Function
(i) Mineral oils and other hydrocarbon Base oil
(ii) Polyglycoether (water soluble) Emulsifier
(iii) Aliphatic amines (water soluble) Neutralizing agent
(iv) Aliphatic amines in neutralized form Corrosion protection
(v) Sulfonates Corrosion protection, pressure
additive
(vi) Fatly acid amides Lubricity Improvement
(vii) Sulphur / Phosphorous additives Pressure additives
(viii) Aldehyde Derivatives Biocides
(iv) Water Soluble Cutting Fluids
These are also called water based cutting fluids. These comprise of
mineral oils, fat mixtures and emulsifiers added to water. The oil is held in
the form of microscopic droplets (colloidal) in water, which assumes a white
milky appearance. Because of water, these have very good cooling effects.
Mixture is prepared in different ratios of cutting oil and water to get the
desired heat transfer and lubricating characteristics.
(iii) High jet method: A narrow jet at high velocity is directed at the flank
surface of the tool. It is the most recent method.
Given:
Feed force (Fd 100 kgs, cutting force Fc 375 kgs, rake Angle
12 Chip thickness ratio r 0.3
1.90 Machine Tools and Digital Manufacturing
Solution:
Given:
Depth of cut t1 0.3 mm, Chip thickness ratio r 0.5, Width of cut
b 6 mm, Cutting Velocity Vc 60 m/min, Cutting force Parallel to cutting
velocity Fc 1200 N, Cutting force normal to cutting Velocity
Fd 160 N, Rake angle 12
Solution
We know that F
F2c F2d
12002 1602
F 1210 N
. 0.356
Given:
From tool signature we have rake angle 12 Feed
f 0.7 mm/rev, depth of cut d 3 mm, cutting speed Vc 60 m/min,
Shear Angle 15.
Power for machining P 6 kW, Idle Power PI 1 kW.
Solution
Pc 5 kW
Fc 60 Vc 60 m/min
3
50 10
60 60
m/sec
60
50 103
Cutting force Fc 60 50 kN
60
r cos 12
tan 15
1 r sin 12
r 0.978
0.268
1 0.208 r
r 0.2593
t Feed 0.7 mm
50 103
Pressure P 23.81 kN/mm2
3 0.7
Feed 0.7
tc 2.7 mm
Chip thickness ratio 0.2593
1.94 Machine Tools and Digital Manufacturing
Solution
(i) Coefficient of friction
Fc tan Fd 300 tan 40 100
Fc Fd tan 300 100 tan 40
1.628
Solution:
(i) To Calculate Shear Angle
r cos
We know that tan
1 r sin
t1 0.3
Chip thickness ratio r 0.857
t2 0.35
Vc cos
Shear Velocity Vs
cos (From Eqn. 1.25)
50 cos 15
73.8 m/min
cos 34.12 15
s Vs
Shear Energy Es
Vc sin (From Eqn. 1.32)
1681.7 73.8
Shear Energy 4425 N/mm2
50 sin 34.12
200
444.44 kg/mm2
0.3 1.5
Given:
Width w 2.5, Uncut chip thickness t1 0.25 mm, Rake Angle
0, Chip thickness t2 1.25 mm, Cutting force Fc 900 N, Thrust
Force Fd 810 N, Coefficient of friction 0.5
Solution
Machining Constant Cm 2
2 11.31 26.565 0
Cm 49.185
Problem 1.8 In an orthogonal machining with a tool rake angle of 10, the
chip thickness was found to be 3 mm when the uncut chip thickness is set
to 0.5 mm. Find the Shear Angle and friction angle [Assume Merchant
formula is holding good for the machining].
Given:
Rake Angle 10, Chip thickness t2 3 mm, Uncut chip thickness
t1 0.5 mm
r cos
Shear Angle : tan
1 sin
r cos
tan 1
1 r sin
0.167 cos 10
tan 1
0.167 sin 10
1
0.1645
tan 1 9.613
0.971
Theory of Metal Cutting 1.99
Given:
Outer diameter Do 80 mm,
Wall thickness tw 4 mm, N 150 r pm, f 0.4 mm/rev,
Cutting ratio 0.25, Fc 1000 N, Fd 500 N
Solution
1. Chip Velocity
Velocity of Chip
Cutting ratio
Velocity of workpiece
Velocity of workpiece V D N in m/min
Where D Mean diameter
Do di
D
2
di Do 2tw 80 2 4 72 mm
80 72
D 76 mm
2
Velocity of workpiece V 76 150 35814 mm/min
V 35.814 m/min
Velocity of Chip Vc 0.25 35.814 8.954 m/min
1000 35.814
P 570 watts
60
Problem 1.10 In an orthogonal cutting of a mild steel, following were
observed cutting force 1200 N, Feed force 500 N, Cutting velocity
100 m/min Rake Angle 12 and shear plane angle is 20. Determine the
following (i) Shear velocity (ii) Chip flow Velocity (iii) Work done per
minute in shearing and against friction (iv) show that work input is sum of
work done in shearing and friction.
Given:
Cutting force Fc 1200 N, Feed for ce Fd 500 N, Cutting Velocity
Vc 100 mm/min. rake angle 12 Shear Angle 20
Solution
Fs 956.62 N
956.62 98.78
Ws 1575 W
60
Theory of Metal Cutting 1.101
738.57 34.54
Work done in friction WF Ff Vt
60
425.17 W
1200 100
Work input WI Fc V 2000 W
60
Hence WI W
V, m/min – 25 35
T, min – 90 20
Calculate (i) n and C (ii) Hence recommend the cutting speed for a desired
tool life of 60 min
Given:
Feed f 0.2 mm/r ev, d 2 mm ; Taylors Eqn.
n
VT C, V1 25 m/min, V2 35 m/min, T1 90 min, T2 20 min
Solution
V1Tn1 C V2 Tn2
25 90n 35 20n
n
90 35
20 25
4.5n 1.4
n log 4.5 log 1.4
log 1.4
n 0.223
log 4.5
Now
V1Tn1 C
C 25 900.223 68.192
Again V3 Tn3 C
68.192
V3 27.37 m/min
600.223
Cutting Speed V3 27.37 m/min
Problem 1.12 A HSS tool gave a tool life of 120 min at 15 m/min and 25
min at 70 m/mm. Calculate (i) C and n for Taylor’s equation. (ii) Cutting
Speed for minimum life say 1 min?
Given:
T1 120 min, V1 15 m/min, T2 25 min, V2 70 m/min
Solution
V1 Tn1 V2 Tn2
Theory of Metal Cutting 1.103
15 120n 70 25n
n
120 70
25 15
n log 4.8 log 4.67
log 4.67
n 0.9825
log 4.8
Now, V1 Tn1 C
C 15 1200.9825 1655.33
The Taylor Equation is VT0.9825 1655.33
Given:
For HSS tool VT0.2 C2 and
Solution:
VT0.2 C2
50 1000.2 C2
VT0.3 C1
1.104 Machine Tools and Digital Manufacturing
50 1000.3 C1
C2 125.6 ; C1 199.1
150 T0.3
1 199.1
1/0.3
199.1
T1 2.57 min
150
HSS Tool VT0.2 C2
150 T0.2
2 125.6
1/0.2
125.6
T2 0.412 min
150
T1 2.57
6.24
T2 0.412
Given:
VT0.3 f0.4 d0.2 C, T 100 min, V 50 m/min,
f 0.5 mm, d 1 mm
Solution