Mechanics of Cutting

Geometry of chip Formation:

tc : Chip thickness
tu : Uncut chip thickness
V f : Chip Sliding Velocity
Vs : Shear Velocity
Vc : Cutting Velocity
φ : Shear Angle
∆ABC & ∆ABD
t
AB = u
sinφ φ
tc tc
also, AB =
sin(90 − (φ − α )) cos(φ − α )
tu sin φ
90-ф+α = 90-(ф-α)
=
tc cos(φ − α ) Fig: Schematic of Geometry of chip formation
SHEAR ANGLE AND CHIP THICKNESS RATIO EVALUATION
tu
rc = : Chip thickness Ratio / Coeffinicient Substitute the value of tu /tc
tc
from earlier slide and simplify to get:
1 cosφ cosα + sinφ sinα
=
rc sinφ
1 rc cotφ cosα + rc sinα
rc cosα= (1 − rc sinα ) tan φ
φ
 rc cosα 
∴ tan φ =
  90-ф+α
 1 − rc sinα  = 90-(ф-α)

How to determine φ & rc ?

tc should be determined from the chip. tu (= feed) and α are already
known.
To determine tc with micrometer, is difficult and not so because of
uneven surface. How? (say, f=0.2 mm/rev. An error of even 0.05 mm will cause
an error of 25 % in the measurement of tc)
Volume Constancy Condition: Volume
Dr. V.K.jain, of Uncut chip = Volume of cut chip
IIT Kanpur 3
SHEAR ANGLE AND CHIP THICKNESS RATIO EVALUATION

Lu tu b = Lc tc b Lc = Chip length
∴ Lc tc =
Lu tu L u = Uncut chip length
b = Chip width
tu Lc
or , r=
c = (2-D Cutting)
tc Lu
LENGTH OF THE CHIP MAY BE MANY CENTIMETERS HENCE THE ERROR IN EVALUTION OF
rc WILL BE COMPARATIVELY MUCH LOWER.

(rc = Lc / Lu)

Dr. V.K.jain, IIT Kanpur 4

 FORCE CIRCLE DIAGRAM

α
Chip
G Tool
Fs
F E Fc ∅ Clearance Angle
α A

B Work
Ft
α Fn
R

∅ α
F Δ FAD = (β - α)
Δ GAD = φ + (β - α)
β
D N

79
 Force Analysis
Forces in Orthogonal Cutting:
• Friction force, F
• Force normal to Friction force, N G
• Cutting Force, FC
F
• Thrust force, Ft A
• Shear Force, FS
•Force Normal to shear force, Fn
•Resultant force, R

C
Force Circle Diagram

FREE BODY DIAGRAM

→ →
R =' F + N
→ → → → →
R = F S + F N = F c + Ft = R '
Dr. V.K.jain, IIT Kanpur 6
 Force Analysis

=F Ft cosα + Fc sinα

=N Fc cosα − Ft sinα

Coefficient of Friction ( µ )

F Ft cosα + Fc sinα
µ tan β
= = =
N Fc cosα − Ft sinα

β = Friction Angle DIVIDE R.H.S. BY Cos α

Ft + Fc tanα
µ= also, β = tan −1 ( µ )
Fc − Ft tan α
Dr. V.K.jain, IIT Kanpur 7
 Foce Analysis

=FS Fc cosφ − Ft sinφ

=FN Ft cosφ + Fc sinφ

also,

=FC R cos ( β − α ) Δ FAD = (β - α)

Δ GAD = φ + (β - α)
FS R cos (φ + β − α )
=

FC cos ( β − α )
∴ =
FS cos (φ + β − α )

t u b  tu 
ShearPlaneArea (=
AS ) =  ×b
sin φ  sinφ 
Dr. V.K.jain, IIT Kanpur 8
 Foce Analysis
Let τ be the strength of work material
tu b
= Sτ
FS A= τ
sinφ

 t bτ   cos ( β − α )   t bτ  
1 
FC =  u    and =
, R  u × 
 sinφ  cos (φ + β − α )   sinφ   cos (φ + β − α ) 

tu bτ sin( β − α )
Ft = R sin( β − α )= ×
sinφ cos (φ + β − α )

Ft
= tan( β − α )
Fc
Dr. V.K.jain, IIT Kanpur 9
 Foce Analysis

FS
Mean Shear Stress (tchip ) =
AS
(On Chip )
( Fc cosφ − Ft sinφ ) sin φ
=
b tu

FN
Mean Normal Stress (σ chip ) =
AS
(On Chip )

( Ft cosφ + Fc sinφ ) sin φ

=
b tu

Dr. V.K.jain, IIT Kanpur 10

 VELOCITY ANALYSIS

Vc : Cutting velocity of tool relative to workpiece

V f : Chip flow velocity

Vs : Shear velocity

Using sine Rule:

Vc Vf Vs
= =
sin(90 − (φ − α )) sin φ sin(90 − α )

Vc Vf Vs Vc sin φ
= = and V = = Vc ⋅ rc
cos(φ − α ) sin φ cos α cos(φ − α )
f

Vc cos α V cos α
=Vs =
⇒ s 11
cos(φ − α ) Vc cos(φ − α )
 Shear Strain & Strain Rate

Two approaches of analysis:

Thin Plane Model:- Merchant, PiisPanen, Kobayashi & Thomson

Thick Deformation Region:- Palmer, (At very low speeds) Oxley, kushina,
Hitoni

Thin Zone Model: Merchant

ASSUMPTIONS:-
• Tool tip is sharp, No Rubbing, No Ploughing
• 2-D deformation.
• Stress on shear plane is uniformly distributed.
• Resultant force R on chip applied at shear plane is equal, opposite and
collinear to force R’ applied to the chip at tool-chip interface. 12
 Expression for Shear Strain
The deformation can be idealized as a process of block slip (or preferred
slip planes)

deformation
ShearStrain(γ ) =
Length

∆s AB AD DB
γ = =
= + = tan(φ − α ) + cot φ
∆y CD CD CD

sin(φ − α ) sin φ + cos ϕ cos(φ − α ) cos α

∴γ =
sin φ cos(φ − α )
, sin φ cos(φ − α )
Dr. V.K.jain, IIT Kanpur 13
 Expression for Shear Strain rate
In terms of shear velocity (V s ) and chip velocity (Vf), it can be written as

Vs  Vs cos α 
∴ γ =  since 
Vc sin φ  Vc cos(φ − α ) 

•
Shear strain rate (γ )
 ∆s 
 
• d γ  ∆y   ∆s  1
γ =
= =  
dt dt  ∆y  ∆y
Vs Vc cos α
= =
∆y cos(φ − α )∆y

where, ∆y : Mean thickness of PSDZ

Dr. V.K.jain, IIT Kanpur 14
 Shear angle relationship
• Helpful to predict position of shear plane (angle φ)

• Relationship between-
Shear Plane Angle (φ)
Rake Angle (α)
Friction Angle(β)

Several Theories
Earnst-Merchant(Minimum Energy Criterion):
Shear plane is located where least energy is required for shear.

Assumptions:-
• Orthogonal Cutting.
• Shear strength of Metal along shear plane is not affected by
Normal stress.
• Continuous chip without BUE.
• Neglect energy of chip separation. Dr. V.K.jain, IIT Kanpur 15
 Shear angle relationship
Assuming No Strain hardening:
dFc
Condition for minimum energy, =0
dφ
dFc  cos φ cos(φ + β − α ) − sin φ sin(φ + β − α ) 
τ tu b cos (β − α )  
dφ  sin φ cos (φ + β − α )
2 2

=0

∴ cos φ cos(φ + β − α ) − sin φ sin(φ + β − α ) =

0
cos(2φ + β − α ) =
0
π
2φ + β − α =
2
π 1
∴φ = − (β − α )
4 2
Dr. V.K.jain, IIT Kanpur 16
THANK YOU

Dr. V.K.jain, IIT Kanpur 17