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Theory of Metal
Cutting
Chapter 4
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Typical Metal
Cutting Operation
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Machining or Metal
Cutting
Removing unwanted material
Cutting/chipping/machining/
metal cutting
To get desired
Shape
Size
Surface finish
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Typical Machining Example
(a) Raw Material
Unwanted material
to be removed
(b) Finished Product
Changing shape/size/finish
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Metal Cutting: features
Closer dimensional accurac
Surface te!ture/finish
"conomical
Comple! shape
Size
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Metal Cutting: features
#aterial loss $%&0'(
Scarcit of materials
Special e)uipment
Skilled operators
Time re)uired
*ll materials cannot +e machined
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Essentials of Metal
Cutting Operation
, #achine Tool
, Cutting Tool
, #ethod
, -perator
A typical
Cutting ool
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Machine Tool
#achine used for metal cutting
provision for holding workpiece
provision for holding tool
relative motion +etween them
providing power/energ
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Typical Machine tool
Ram
ool
!or"piece
#ise
$ase
v
able
f or d
ool head
d or f
Column
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Different Machine Tools
Tpe of surface .
flat/circular/comple!
#etal Cutting #achine Tools
#etal /orming #achine Tools
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Classification of
Machine Tools
degree of specialization
general/special
surface
cylidrical/flat
motion
recipocatory/rotary
duty cycle
L/M/H
automation
manual/semi-auto/auto
energy
conventional/non-conventional
Mechanism of Metal
Cutting
Tool & Workpiece interaction
Force
ool

!or"piece
ool penetration
(depth of cut)
Relative motion
between tool and
wor"piece (cutting speed)
Chip
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Cutting Tools
Re)uirements
Common materials
*lloing
Tpes
Tool geometr
sharp edge/strong/hard/tough
shape/size/method of holding
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Types of Tools
Single Point
Multipoint
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Metal Cutting ..
0asics
Features
Essentials
#achine Tools
Different
Classification
Mechanism of Metal Cutting
Cutting Tools
Requirements
Tool Materials
Types of tools
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Geometry of ingle !oint Tool..
Tool ignature
8 14 6 8 8 19 1
% & $ac" Ra"e Angle
'4 & (ide Ra"e Angle
) & *nd+relie, Angle
% & (ide Relie, Angle
% & *nd Cutting *dge Angle
'- & (ide Cutting *dge Angle
' & .ose Radius
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Geometry of ingle !oint Tool..
R" # $" Tool
Right hand tool 1eft hand tool
(ide cutting
*dge

(ide cutting
*dge
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Orthogonal an% O&lique
Cutting
Orthogonal cutting Oblique cutting
Cutting edge
at -/0
Machined
Motion o,
!or"piece
Motion o,
!or"piece
Chip
Chip
ool
ool
Cutting edge
inclined
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Types of Chips
$uilt+up
edge
ool
!or"piece
Chip
Chip
Continuous
chip
1iscontinuous
chip
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Types of Chips ..
2orkpiece material
Tool geometr
Cutting conditions
, Continuous Chip . chip +reaker
, 3iscontinuous Chip
, Chip with 0uilt4up "dge
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Thermal 'spects in
Machining
5eat generated in cutting operation
depends6
Rate of Cutting
cutting conditions
2orkpiece material
effects6
78Tool
282orkpiece
38#achine tool
, Surface
, accurac
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Thermal 'spects in Machining..
Distri&ution of "eat
heat generated in machining
operation
chips9tool9workpiece9environment
: ; :7 9 :2 9 :3 9 :<
:7;heat taken awa + the chips
:2;heat conducted in to tool
:3;heat conducted in to workpiece
:<;heat dissipated in environment
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Thermal 'spects in Machining..
Distri&ution of "eat..
5eat dissipation
, depends on cutting speed
Cutting (peed v
2

3
e
a
t
ool '/2
!or" '/2
Chips %/2
To keep cutting
zone temperature
low
Cooling
Cutting /luid
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Cutting Flui%s
absorb and carry away the heat
cool the workpiece and tool.
reduce the friction
wash away the chips.
carry away the built-up edges
formed.
give very fine surface finish
prevent corrosion
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Operating Con%itions
Conditions $motions( re)uired for
metal cutting to take place
-perating or Cutting Conditions
Cutting Speed v . m/s
/eed f . mm/s or mm/rev or
mm/min
3epth of Cut d . mm
#aterial Removal Rate #RR . m
3
/s
#achining/Cutting Time
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Tool $ife
2ear of sharp edge dull tool
time +etween two successive
resharpenings
Time for which tool cuts effectivel
=nfluencing /actors
78 -perating/cutting
conditions
28 2orkpiece material
38 Tool material
<8 >eometr of tool
&8 ?se of Coolant
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Tool $ife ..
Cutting Speed $v(
tool life $T(
log v
log T

4ntercept (log C)
(lope (n)
'
5
/
Talor@s
"!pression
or
Tool 1ife
")uation
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Tool $ife..
Taylor(s Expression
vT
n
;C
v ; Cutting Speed $m/min(
T ; Tool 1ife $min(
nA C are constants8 C ; =ntercept
n ; Slope of line
5 '
5 '
log log
log log
tan
T T
v v
n

= =
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Tool $ife..
Typical n # C )'$*E
2ork
material
Tool
material
n C
Steel
5SS 0874087B 7B047C0
Car+ide 087D4082 22042C0
Cast =ron
5SS 080D4087 70047D0
Car+ide 0824082D 2&0432&
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Tool $ife..
"ffect of depth of cut and feed on tool
life
log v
log f
log d
log T
d
v
1
' > 5 > 6
2
f
3
C d f vT
n n n
=
5 '
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Machina&ility
"ase of machining
, Tool life
, Cutting Speed
, /orce/power
, *ccurac/finish
* relative measure
,Cutting /orces/power
,specific cutting speed . CS for
tool life T
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Machina&ility ..
#achina+ilit; $v
t
/v
s
( ! 700'
v
s
. specific CS for standard material
v
t
. specific CS for test material
#achina+ilit is affected +
, Condition of machine/tool
, Cutting conditions
, Tpe of operation
, work material
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E+'M!$E ,.-
2hile machining car+on steel + a tungsten
+ased steel toolA tool life of &0 minutes
was o+served when machined with a
cutting speed of 700 m/min8 3etermine
$a( >eneral Talor@s tool life e)uation and
$+( tool life for a cutting speed of
D0 m/min8 *ssume n ; 080C8
2ork material6 car+on steel
Tool material6 tungsten +ased tool steel
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E+'M!$E ,.- ..
olution
>iven6 v ;700 m/minA T ;&0 minA n ;080C
Talor@s ")n8 vT
n
;C
or 1og v 9 n log T ; log C
or 1og 7009 080C log &0 ; log C
or C ; 7<2820
5ence6 vT
080C
;7<282
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E+'M!$E ,.- ..
olution
$+(
>iven6 vT
080C
;7<282A v ; D0 m/minA
T ; E
D0 8T
080C
;7<282
or T; &CB8&F min
"G*#H1"S
Example 4.3 * car+ide4cutting tool
when machined with mild steel
workpiece material at a cutting speed of
&0 m/min lasted for 700 minutes8
3etermine the life of the tool when the
cutting speed is increased + 2&'8 *t
what speed the tool is to +e used to get
a tool life of 7D0 minute8 *ssume n ;
082B in the Talor@s e!pression8
"G*#H1"S
Solution: >iven data6 v7 ; &0 m/minA
T7 ; 700 minA n ; 082B
/or 20' higher speed
v2 ; 782&v7 ; B28& m/min
2e know that v7 T7In ; v2 T2In
Su+stituting the valuesA we get
T2 ; <283C minutes
"G*#H1"S
$+( 1et v3 +e the cutting speed for tool
life of 7D04min8
2e know that
v7T7In ; v3T3In
Su+stituting the valuesA we get
v3 ; <28C7 m/min
"G*#H1"S
Example 4.4 =n assessing
machina+ilit of different workpiece
materialsA the following data were
o+tained during machining6
2ork mat Tool life Cutting speed
* 2& 700
70 7&0
0 <0 200
20 2&0
"G*#H1"S
"stimate the relative machina+ilitA
considering material * as standard material
and tool life as cutting speed of &0 m/min as
criteria8
Solution Consider material *
J7;700 m/min8 t7;2& min J2;7&0 m/min
t2;70 min8
2e know that
log J 9 n log t ; log C
"G*#H1"S
Su+stituting we get
log 700 9 n log 2& ; log C
log 7&0 9 n log 70 ; log C
Solving e)uations $7( and $2(A we get
n ; 08<3 and C ; <038&&
5enceA tool life e)uation is J t08<3 ; <038&&
"G*#H1"S
To find speed at t ; &0 min8
Su+stitute t ; &0 min e)uation $3( we get
JB0; F& m/min8
Repeating the same procedure for material 0
we get
n;0833 AC;B37 and JB0 ; 7F38&3 m/min8
Relative machina+ilit ; KJB0 for test material
/ JB0 for standard materialL 700
; K7F38&3/F&L 700
; 23783F'