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Manufacturing Processes II
Manufacturing Processes II
3 Year Materials Engineering
rd
By
Dr. Eng. Alaa A. Ateia
PhD. Metallurgical Eng.
Manufacturing Processes II
CHAPTER ONE
CUTTING ENGINEERING
1. Basic cutting tools
1.1 Cutting speeds, feeds, tools and times
Cutting is a balance between a number of factors,
1. Cutting slowly will add costly time to manufacturing operations.
2. Cutting faster will lead to decreased tool life, and extra time will be required to
repair tools.
Some reasonable speeds and feeds for a single cutting point tool are given below.
The cutting velocity is higher, but the feed/depth of the cut is reduced, the resulting
mrr is still higher.
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Higher spindle speeds call for new low inertia spindle and tolerances as well.
Small tolerance problems can result in unacceptable vibrations at these speeds.
2. Cutting theory
When we cut metal, the severed pieces are cast off; these are referred to as chips.
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We can obtain orthogonal cutting by turning a thin walled tube, and setting the lath bit
cutting edge perpendicular to the tube axis.
Next, we can begin to consider cutting forces, chip thicknesses, etc.
First, consider the physical geometry of cutting,
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Next, we assume that we are also measuring two perpendicular cutting forces that are
horizontal, and perpendicular to the figure above. This then allows us to examine specific
forces involved with the cutting. The cutting forces in the figure below (Fc and Ft) are
measured using a tool force dynamometer mounted on the lathe.
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Having seen the vector based determination of the cutting forces, we can now look at
equivalent calculations
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Manufacturing Processes II
Manufacturing Processes II
1. Should be enough to include both the measured forces. The cutting force (Fc) is
drawn horizontally, and the tangential force (Ft) is drawn vertically. (These forces
2. will all be in the lower left hand quadrant) (Note: square graph paper and equal x
& y scales are essential)
3. Draw in the resultant (R) of Fc and Ft.
4. Locate the centre of R, and draw a circle that encloses vector R. If done correctly,
the
5. Heads and tails of all 3 vectors will lie on this circle.
4. Draw in the cutting tool in the upper right hand quadrant, taking care to draw the
correct rake angle () from the vertical axis.
5. Extend the line that is the cutting face of the tool (at the same rake angle) through
the
6. Circle. This now gives the friction vector (F).
7. A line can now be drawn from the head of the friction vector, to the head of the
resultant vector (R). This gives the normal vector (N). Also add a friction angle
() between vectors R and N. As a side note recall that any vector can be broken
down into
8. Components. Therefore, mathematically, R = Fc + Ft = F + N.
6. We next use the chip thickness, compared to the cut depth to find the shear force.
To do this, the chip is drawn on before and after cut. Before drawing, select some
magnification factor (e.g., 200 times) to multiply both values by. Draw a feed
thickness
9. Line (t1) parallel to the horizontal axis. Next draw a chip thickness line parallel to
the tool cutting face.
7. Draw a vector from the origin (tool point) towards the intersection of the two chip
lines, stopping at the circle. The result will be a shear force vector (Fs). Also
measure the
10. Shear force angle between Fs and Fc.
8. Finally add the shear force normal (Fn) from the head of Fs to the head of R.
9. Use a scale and protractor to measure off all distances (forces) and angles.
11. The resulting diagram is pictured below,
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