Effect of metal cutting parameters on chip reduction co-efficient

Topics:
Introduction Mechanics of chip formation Types of chips produced in metal cutting Mechanics of oblique cutting Temperature in cutting Tool life : Wear and failure Surface finish and integrity Cutting forces

Introduction:
Cutting process : Remove material from the surface of the work piece by producing chips. Turning operation : The work piece is rotated and a cutting tool removes a layer of material by shearing process along the shear plane. Slab-milling: Rotating cutting tool removes a layer of material from the surface of the work piece. End-milling: Rotating cutter travels along a certain depth in the work piece and produces a groove

Fundamentals of cutting:

Factors influencing cutting process:

Cutting speed depth of cut, feed, and cutting fluids. Tool angles Continuous chip Built-up-edge chip Discontinuous chip Temperature rise. Tool wear

Forces power, temperature rise, tool life, type of chips, surface finish. As above; influence on chip flow direction ; resistance to tool chipping. Good surface finish; steady cutting forces; desirable, opt end in cutting ductile material. Poor surface finish, changes the tool the tool geometry, undesirable, opt end while cutting ductile material at slow cutting speed. Desirable for ease of chip disposal; fluctuating cutting forces; can affect surface finish and cause vibration and chatters, opt end while cutting brittle material. Influences surface finish, changes dimensional accuracy, reduces the tool life. Influences surface finish, dimensional accuracy, temperature rise, forces and power

Mechanics of chip formation:

= Rake angle, = Shear angle, = Relief angle/Clearance angle, t = Uncut chip thickness, tc = Chip thickness after cut.

Shear plane: The material ahead of its sheared continuously along a plane called the sheared plane. (Generally it is .025mm) Rake surface: The surface along which the chips move upwards is called Rake surface. Rake angle: The angle between Rake surface and the normal is called Rake angle. Relief angle: The angle between flank and horizontal is called Relief angle or Clearance angle.

Mechanism of chip formation:

Shear strain = S= AB/OC = AO/OC + OB/OC =Cot + tan () Note : for actual cutting operation shear strain > 5 Shear angle adjusts itself to minimize cutting force Shear plane is the plane of maximum shear stress

= Friction angle = co-efficient of friction Continuous chip, Discontinuous chip, Built up edge.

Types of chips:

Basic types of chips and their photomicrographs produced in metal cutting (a) continuous chip with a narrow, straight primary shear zone; (b) secondary shear zone at the chip tool interface;(c) continuous chip with large primary shear zone; (d) continuous chip with built-up-edge;(e) segmented or no homogeneous chip and (f) discontinuous chips

(a) Hardness distribution in the cutting zone for 3115 steel . Note that some regions in the built-up edge are as much as three times harder than the bulk metal, (b) Surface finish in turning 5130 steel with a built-up edge, (c) Surface finish on 1018 steel in face milling.

Advantage of Continuous chips:

Continuous chips are usually formed at high rake angles and or high cutting speeds. A good surface finish is generally produced.

 Continuous chips are not always desirable, particularly in automated machine tools. Tend to get tangled around the tool. Operation has to be stopped to clear away the chips

Built-up edges chips:

BUE consists of layers of material from the work piece that are gradually deposited on the tool. BUE then becomes unstable and eventually breaks up. BUE material is carried away on the tool side of the chip. The rest is deposited randomly on the work piece surface. BUE results in poor surface finish. Reduced by increasing the rake angle and therefore decreasing the depth of cut.

Discontinuous chips:
Discontinuous chips consist of segments that may be firmly or loosely attached to each other These chips occur when machining hard brittle materials such as cast iron. Brittle failure takes place along the shear plane before any tangible plastic flow occurs Discontinuous chips will form in brittle materials at low rake angles (large depths of cut).

Chip Breakers:
Long continuous chip are undesirable. Chip breaker is a piece of metal clamped to the rake surface of the tool which bends the chip and breaks it. Chips can also be broken by changing the tool geometry , thereby controlling the chip flow.

Various chips produced in turning: a) tightly curled chip b)chip hits work piece and breaks c)continuous chip moving away from work piece d)chip hits tool shank and breaks off.

Mechanics of Oblique Cutting:

The cutting edge is at an angle i, called inclination angle. The chip movement is in lateral direction.

Temperature in Cutting:

Fig: Typical temperature distribution in the cutting zone, Fig: Percentage of the heat generated in cutting going into
the work piece, tool,and chip, as a function of cutting speed.

Temperature Distributions:

Fig:Temperatures developed in turning 52100 steel: a) flank temperature distribution;and b)tool-chip interface temperature distribution.

Tool Life: Wear and Failure:

Flank wear: It occurs on the relief face of the tool and the side relief angle.

Crater wear: It occurs on the rake face of the tool. Chipping: Breaking away of a small piece from the cutting edge of the tool

Wear and Tool Failures: Crater wear:

(a) types of wear observed on various types of cutting tools. (b) catastrophic tool failures . A study of the types and mechanism of tool wear and failure is essential to the development of better tool materials.

Forces acting in 2-Dimensional cutting:

Cutting forces can be measured by using suitable dynamometers or force transducers mounted on the machine tool They can also be calculated from the amount of power consumption , that occurs during cutting.