Fundamentals of Chip-Type

Machining Processes
Chapter 20

Why machine parts?

Create prototypes, models, molds, tool and

dies, one-offs,
Repair parts
Create unique features

Sharp corners
O-ring grooves
Flat, smooth surface for mating two pieces
Curved, mating surfaces (piston and cylinder)

Produce a part(s) dimensionally more

accurate than castings
When it is not economical to cast

Types of Parts Machined

Shafts
Tube fittings
Molds for plastic injection molding of
parts
Fasteners (bolts, screws, nuts)
IC engine parts
Tool and dies for stamping
Bearings, gears, sprockets
Jewelry

Materials that can be

machined

Metal
Wood
Plastics
Ceramics
Composites (cutting, drilling, finishing)
Stone (include jewelry)
Concrete (cutting, drilling)

Basic Machining Processes

Shaping
Turning
Milling
Drilling
Sawing
Broaching
Grinding

Variables in the Machining

Process

Independent Variables

Tooling
Workpiece material, condition,
temperature
Machining Parameters
Cutting Fluid
Machine tool
Fixturing

Variables in the Machining

Process

Dependent Variables

Type of chip produced

Force and energy dissipated in the
cutting process
Temperature rise in workpiece, chip,
tool
Wear and failure of the tool
Surface finish produced

Basic Machining Parameters

Speed (V)

Primary motion provided by a

machine tool
Relative motion between tool and
workpiece
Usually absorbs most of the total
power required
Units: Surface feet per minute (sfpm)

Basic Machining Parameters

Feed (fr)

May proceed continuously or in steps

Usually absorbs a small portion of
total power
Unit: Inches per something stroke,
revolution, etc.

Basic Machining Parameters

Depth of Cut (t)

Third dimension
Constant
Units: inches (or mm)

Basic Machining Parameters

Material Removal Rate

Volume of cut
MRR =
Cutting Time

Chip Formation

Localized shearing
process
Material is
compressed and
plastically
deformed.

large strains
high strain rates
work hardens; fails
by a shearing
process

Shearing defined by
the shear angle, .

Chip Formation

Three basic types

Discontinuous chips
Continuous chips
Continuous chips with a built-up edge
(BUE)

Chip Formation

Discontinuous chips

Typically associated with brittle metals

like Cast Iron
As feed is increased, some compression
takes place
As the chip starts up the chip-tool
interference zone, increased stress
occurs until the metal work-hardens to
a maximum and fractures off the part.

Chip Formation

Discontinuous chips

Chip Formation

Conditions for Discontinuous

chips

Brittle work material

Small rake angles on cutting tools
Coarse machining feeds
Low cutting speeds
Major disadvantagecould result in
poor surface finish

Chip Formation

Continuous Chips

Continuous ribbon of metal that

flows up the chip/tool zone.
Usually considered the ideal
condition for efficient cutting action.

Chip Formation

Problems with Continuous

Chips

Increased frictional heating from

remaining in contact with the tooling
longer.
Greater chance of worker injury
Metal ribbon can become tangled in
tooling

Chip Formation

Conditions for Continuous

Chips

Ductile work
Fine feeds
Sharp cutting tools
Larger rake angles
Proper cutting speeds
Proper coolants

Chip Formation

Continuous chips
with a built-up
edge (BUE)

Same process as
continuous, but as
the metal begins to
flow up the chip-tool
interface, small
particles of the metal
begin to adhere or
weld themselves to
the edge of the
cutting tool.

Chip Formation

Continuous chips
with a built-up
edge (BUE)

As the particles
continue to weld to
the tool it effects
the cutting action
of the tool including
the beginning of
galling.

Chip Formation

Conditions for a built-up edge

(BUE)

Common in softer non-ferrous

metals and low carbon steel.
Formation increases as the tool
begins to dull.

Chip Formation

Problems with a built-up edge

(BUE)

Welded edges break off and can

become embedded in work-piece
Decreases tool life
Can result in poor surface finishes

Chip Formation

Solution be a built-up edge

(BUE)

Reduce depth of cut

Alter cutting speed
Use positive rake tool
Coolant
Use different cutting tool materials

Chip Breakers

Two styles of chip breakers

Groove
Obstruction

Orthogonal Machining

Orthogonal
Cutting is when
the cutting edge
of the tool is
straight and
perpendicular to
the direction of
motion.

Oblique Machining

Most machining is performed with

oblique geometry.

Oblique Machining

Tool edge is set at an angle of

inclination, i.
Effective rake angle is larger than
normal rake angle, thus cutting
force is lower.
Chip curls into a helical rather than
a spiral, easily removed.

Oblique Machining

Oblique machining
has 3 components
FC Primary cutting
force

acts in the direction

of the cutting force
vector.
Largest force
(generally)
99% of the power

Oblique Machining

Ff Feed force

Acts in the direction of the tool feed.

~ 50% FC
Small power requirement

Fr radial force

acts perpendicular to the machined surface

~ 50% Ff
very small power requirement

Power
HP = FC V
HP =

FC V
33000

Specific Horsepower
HP
HPS
MRR
Specific Horsepower correlates with shear stress.

Power

HPs is used for

Estimate motor HP for a machining

process for a given material

Estimate Cutting Force (FC)

Determine maximum depth of cut (d)

Energy

30-40% of the total energy goes into

friction.

60-70% of the total energy goes into

the shear process

Table 20-3, U values for common

metals

Shear Strain

Shear strain rates 104 to 108

in/in-sec

Heat and Temperature

Three main
sources of heat

Shear front
Tool/chip
interface
Flank of the
tool

Heat Distribution

Heat and Temperature