MECHANICS OF METAL
CUTTING
By
Khairun Nasrin Rimi
Lecturer
World University of Bangladesh
Cutting Geometry
Metal cutting or machining is the process of producing a work piece by removing unwanted
material from a block of metal, in the form of chips. . This process is most important since
almost all the products get final shape and size by metal removal, either directly or indirectly.
Orthogonal Cutting Model
The degree of thickening of the chip is
expressed by
Chip reduction coefficient, ζ = (The chip
thickness (tc) usually becomes larger than the uncut
chip thickness (t) due to compression of the chip
ahead of the tool, frictional resistance to chip flow,
lamellar sliding)
Cutting ratio , r= =
Cutting Rake surface
Ratio
(or chip thicknes
Sin = and Cos-) =
Chip
ratio) tool
r= B
tc
to
D A
Workpiece 90-
B
90+90- X=180 `
X=
90-
A
Shear plane
It has been observed that during machining, particularly ductile materials, the chip sharply changes its direction of
flow (relative to the tool) from the direction of the cutting velocity to that along the tool rake surface after thickening
by shear deformation or slip or lamellar sliding along a plane. This plane is called shear plane.
Shear plane
Shear plane is the plane of separation of work material layer in the form of chip from the parent body due to shear
along that plane.
Shear angle
Angle of inclination of the shear plane from the direction of cutting velocity.
The value of shear angle, denoted by φ (taken in orthogonal plane) depends upon
• Chip thickness before and after cut i.e. ζ
• Rake angle (in orthogonal plane)
Lc
tc
i n c e , t0 w 0 L0 = t c w c L c and w 0 =w wc
c
r= = t0
L0
w0
Shear Plane Length and Angle
Chip
tool
B
tc
to
A
Workpiece
t0
Shear plane length AB =
sin
-1 rcos
Shear plane angle () = Tan
1-rsin
or make an assumption, such as adjusts to minimize
cutting force: = 45 0 + /2 - /2 (Merchant)
Shear Velocity
Vc= Chip Velocity
(Chip relative to tool) Velocitie
(Chip relative (2D
s
to workpiece)
Vs V = Cutting VelocityOrthogonal
Model
Chip
Tool
(Tool relative to )
workpiece)
Workpiece
Velocity Diagram
Vc
Vs
From m a s s c o n t i n u i t y : V t o = V c t c
V c = V r and sin
V c = V cos()
From the Ve l o c i t y diagram:
V
c os
Vs = V
cos()
Cutting
Forces (2D
Orthogonal
Chi Tool Cutting)
p Generally we know:
Tool geometry & type
R Workpiece material
F
Fs and we wish to know:
Fn R
N F = Friction Force
Fc = Cutting
R Force F t =
Fc Thrust Force N =
Workpiec Ft R Normal
F s = Shear
Force
e F
Force
n
= Force Normal to
Shear
Dynamometer
Free Body Diagram
Cutting Forces (2D Orthogonal Cutting)
Fs , Resistance to shear of the metal in forming the chip. It acts along the shear
plane.
Fn , ‘Backing up’ force on the chip provided by the work piece. Acts
normal to the shear plane.
N, It at the tool chip interface normal to the cutting face of the tool and
is provided by the tool.
F, It is the frictional resistance of the tool acting on the chip. It acts
downward against the motion of the chip as it glides upwards along
the tool face.
Construction of Merchant’ s Circle
Fs
Fn α
Fc φ V
λ-
Ft φ α
R α
λ F
Knowing Fc , Ft , α and ϕ, all other component forces can be calculated.
Please note is same as in
next slide = friction angle
Force Circle
(Merchants
Diagram
Circle)
It’s a Graphical method to calculate the
Tool
forces in machining. Fs
F = Friction Force Fc
N = Normal Force
Fs = Shear Force
Fn = Normal Shear Force F F
t n
It is calculated from the measured
forces R
Fc = Cutting Force
Ft= Thrust Force
F
N
TOO
L
Fc
TOO
L
Fc
F
t
TOO
L
Fc
F
t
TOO
L
Fc
F
t
TOO
L
Fc
F
t
TOO
L
Fc
Ft
TOOL
Fc
Merchant's Circle
F
t
TOO
L
Fc
F
t
TOO
L
Fc
F
t
TOO
L
Fc
F
t
TOO
L
Fc
F
t
TOO
L
Fc
F
t
TOO
L
Fc
F
t
TOO
L
Fc
F
t
TOO
L
Fc
F
t
TOO
L
Fc
F
t
TOO
L
Fc
F
t
TOO
L
Fc
Ff
Ft
TOO
L
Fc
Ff
Ft
TOO
L
Fc
Ff
Ft
TOO
L
Fc
Ff
Ft
TOOL
Fc
Ff
Ft
TOOL
Gh’
'Joe
Fc
Ff
Ft
TOOL
Fc
Fn
Ff
Ft
#Q. During an experiment on machining, the dynamometer showed Fc to be 1557 N and Ft = 1271 N while
the workpiece was machined at a cutting speed of 100 m/min. The rack angle is to be 10°. Depth of cut is set
at 0.5 mm. After machining, the chip thickness was measured to be 1.125 mm ar w = 3 mm.
Determine Fn,Fs, F, N, φ.
Fc=1557 N r = to / tc
Ft= 1271 N
N = 100 m/min rcos-1
γ = 10° () = Tan
1-rsin
to = 0.5 mm
tc = 1.125 mm
w = 3 mm Fn = Fc Sinφ + Ft Cosφ
Fs = Fc Cosφ - Ft Sin
F= Fc Sin 𝛂 + Ft Cos 𝛂
N= Fc Cos 𝛂 - Ft Sin 𝛂
Cutting Tool Materials
• Carbon steels, High-speed steels
• Cast carbides, Cemented carbides, Coated carbides
• Cermets, Ceramic Tools
• Polycrystalline Cubic Boron Nitride (PCBN)
• Polycrystalline Diamond (PCD)
Properties of Cutting Tool Materials
• Harder than work piece.
• High toughness
• High thermal shock resistance
• Low adhesion to work piece material
• Low diffusivity to work piece material
