Metal Cutting Theory and

mechanism

Prepared by : Er. MANISHA YADAV

Introduction
Machining is probably the most expensive
among all the manufacturing process
available (energy and material loss) yet it is
basically adopted to get higher surface
finish, close tolerance and complex
geometry shapes which are otherwise
difficult to obtain.
However all component undergo
machining process at some stages.
Introduction
Material Removal Process
 Various Cutting Operations
Turing – produces straight, conical, curved, or
grooved work pieces

Facing – produces a flat surface at the end of the

part

Boring – to enlarge a hole

Drilling - to produce a hole

Cutting off – to cut off a work piece

Threading – to produce threads

Knurling – produces a regularly shaped roughness

Cutting Operations

Fig : Various cutting

operations that can
be performed on a
late. Not that all
parts have circular
symmetry
Machine Tool
Machine tool is one which while
holding the cutting tool is able to
remove the metal from a work piece in
order to generate the requisite part of
the given size, configuration and finish.
It is different from a machine, which is
essentially a means of converting the
source of power from one form to other.
Functions of machine tool
To hold and support the job or work to
be machined.
To hold and support the cutting tool in
position.
To move the cutting tool, work or both
of them in a desire direction.
To generate the cutting speed and feed.
Types of Machine Tools
Classification of cutting tool
Single Point cutting tool :
Those having only one cutting edge.
Ex: lathe tools, shaper tools , planner tools etc.

Multi-point cutting tool :

Those having more than one cutting edges.
Ex: milling cutters, drills, broaches, grinding wheels
etc.
Cutting Conditions
Single point cutting tool geometry
Important terms
Shank : portion of the tool which is gripped in the
tool holder.
Face: The top surface of the tool between the shank
and the tool point. Chip flows along this surface
only.

Flank:
Base:
Heel:
Nose radius:
single point cutting tool angles
Rake angle: angle formed between the face of the
tool and a plane parallel to its base.
Back rake angle: If the inclination is towards the
shank.
Side rake angle: If the inclination is towards the
side of the tool.
These rake angles guide the chip away from the
cutting edge, thereby reducing the chip pressure on
the face hence less power consumption. Strength of
the tool decreases with increase in rake angle.
Tool angles
Lip angle: angle between the face and flank of the tool.
Larger the lip angle stronger will be the cutting edge.

Clearance angle: angle formed by the front or side

surfaces of the tool with the plane normal to the base
of the tool when tool is in horizontal position.

Cutting angle: The angle formed between the tool face

and a line through the point which is a tangent to the
machined surface.
Tool signatures
Back rake angle (αy)
Side rake angle (αx )
End relief angle (βy)
Side relief angle (βx)
End cutting edge angle (Фe)
Side cutting edge angle (Фs)
Nose radius
Machine Tool Classification
Machine Tool Classification
Chip Formation
Chip formation
Types of chips
Discontinuous chip
Continuous chip
Continuous chip with BUE
Chip with built up edge
Orthogonal and oblique cutting
Orthogonal cutting Oblique cutting
The cutting edge of the The cutting edge of the
tool remains normal to the tool always remains
direction of tool feed or inclined at an acute angle
work feed. to the direction of tool feed
The direction of chip flow or work feed.
velocity is normal to the The direction of chip flow
cutting edge of the tool velocity is at an angle with
The cutting edge is longer the normal to the cutting
than the width of cut. edge of the tool. (i.e chip
flow angle)
The cutting edge may or
may not be longer than the
width of the cut.
Thermal Aspects
Thermal Aspects
Chip Thickness Ratio (r)
Let
t= Chip thickness
prior to
deformation.
tc = Chip thickness
after deformation
or cut chip
thickness.
Velocity Relationship
Where :
V = Velocity of tool relative to work
VC = Velocity of chip flow relative to tool
VS = Velocity of displacement of the chip along
shear plane relative to work or Velocity of shear

VS = V .[ cos α / cos (Ф-α) ]

VC = V.[ Sin Ф / cos (Ф-α) ]
VC =V x r
 
Cylindrical Turning on an Engine
Lathe
Resultant Cutting Motion in
Cylindrical Turning
Single-point Tool Operation
Important Formulas
Length along shear plane ls = ac / sin Ф
Area of chip cross section A0 = a0 aw
Area of unchip cross section Ac = ac aw
Shear Area of chip cross section
As = ls aw
If mass of chip is given as “mc” and density ρ
then :
a0 = mc / lc aw ρ
Q 1. In an orthogonal cutting test on mild steel, the following
results were obtained:
 
Cutting force Fc = 900 N
Thrust force Ft = 450 N
Uncut chip thickness ac = 0.25 mm
Chip thickness a0 = 0.75 mm
Width of cut aw = 2.50 mm, rake angle zero degrees.
Length of contact between chip and tool lf = 0.5 mm
Calculate mean angle of friction on the tool face β.
Calculate mean shear strength of the work material τs.
Calculate the mean frictional stress τf.
Theory of Ernst and Merchant
In their analysis chip is assumed to behave as a
rigid body held in equilibrium by the action of
forces transmitted across chip tool interface and
across the shear plane.

It is assumed that whole of the resultant tool

force is transmitted across the tool chip interface
and that no force acts on the tool edge or flank.
Theory of Ernst and Merchant
The basis of Ernst and Merchant theory was the
suggestion that the shear angle would take up such a
value as to reduce the work done in cutting to
minimum
Q2. In an experimental turning operation where low-carbon
steel was being machined using a carbide tool, the
following data were obtained:
Cutting force Fc = 1 kN
Thrust force Ft = 0.5 kN
Working normal rake γne = 20 deg.
Feed f = 0.141 mm
Working major cutting-edge angle κr = 45 deg.
Depth of cut (back engagement) ap = 5 mm
Cutting speed v = 2 m/s
Cutting ratio rc = 0.2
Work piece diameter dw = 100 mm
Work piece machined length lw = 300 mm.
Estimate from the above data:
a. The specific cutting energy of the work material ps.
b. The power required for machining Pm.
c. The undeformed chip thickness ac.
d. The width of cut aw.
e. The shear angle φ.
f. The mean angle of friction on the tool face β.
g. The time taken to complete the machining operation.