ME497 Machining Dynamics 2177228

Abdul Ahad Naeem

Homework # 1

A set of orthogonal tests are conducted to identify the shear angle, average friction coefficient, and
shear stress of P20 mold steel that has a hardness of 34Rc. The cutting conditions and measured
forces and chip thicknesses are given below. The cutting tool was an S10 grade plunge turning tool
with a zero rake angle. The width of cut (i.e., the width of disk) was b = 5 mm, and the cutting speed
was V = 240 m/min.

Table: Orthogonal cutting test conditions and measurements in plunge turning of P20 mold steel.

Table 1

Feed rate c(mm/rev) Tangential Force Ft(N) Feed Force Ff (N) Measured Chip
Thickness hc (mm)
0.02 350 290 0.050
0.03 480 350 0.058
0.04 590 400 0.074
0.05 690 440 0.083
0.06 790 480 0.102
0.07 890 505 0.116
0.08 980 540 0.131

(a) Evaluate the cutting coefficients Ktc and Kfc [N/mm2] and edge force constants Kte and Kfe
[N/mm] by a linear regression of the measured forces.

From linear regression of tangential force and feed force, we find out the gradients and y-intercepts.
Using the gradients and y-intercepts, the respective coefficients were calculated. The results are
tabulated as follows:

Table 2

Cutting Force Coefficient for Tangential Force, 2078.6

Ktc
Edge Cutting Force Coefficient for Tangential 32.36
Force, Kte
Cutting Force Coefficient for Feed Force, Kfc 814.29

Edge Cutting Force Coefficient for Feed Force, 45.14

Kfe

(b) Evaluate the shear angle ( c ), shear stress ( s  ), and average friction coefficient ( a ) for each
test to form an orthogonal cutting database.

The results are presented as follows:

ME497 Machining Dynamics 2177228

Table 3

Shear Angle (rad) Shear Stress (Pa) Average Friction Angle (rad)
0.381 806.9 0.692
0.477 813.3 0.630
0.496 781.8 0.596
0.542 751.3 0.568
0.532 739.5 0.546
0.543 739.7 0.516
0.548 723.1 0.504

(c) Predict the cutting force coefficients (Ktc, Kfc) using empirically expressed c , s  , and a and
compare them against the values identified from mechanistic linear regression of the forces.

The results obtained for cutting force coefficients using empirical formula are always larger than the
value obtained through mechanistic modelling. The results are tabulated as follows:

Table 4

Cutting Force Coefficient for Tangential Force, Cutting Force Coefficient for Feed Force, Kfc
Ktc
3500.0 2900.0
3200.0 2333.3
2950.0 2000.0
2760.0 1760.0
2633.3 1600.0
2542.9 1442.9
2450.0 1350.0

(d) Using the orthogonal to oblique transformation, express the cutting constants for a helical end
mill that has 30 degrees and 5 degrees of helix and normal rake angles, respectively.

In orthogonal to oblique transformation, friction angle and shear stress remain the same. Moreover,
the orthogonal shear angle is equal to the normal shear angle in oblique cutting, the normal rake
angle is equal to the rake angle in oblique cutting, and the chip flow angle is equal to the oblique
angle. The results are represented as below:

Table 5

Cutting Force Coefficient for Cutting Force Coefficient for Cutting Force Coefficient for
Tangential Force, Ktc Feed Force, Kfc Radial Force, Krc

3468.1 1553.7 1433.9

3045.8 1239.3 2252.2
2816.3 1080.1 2520.0
2592.1 943.6 2813.9
2512.0 876.4 2896.6
2438.5 799.3 3159.9
2353.5 750.6 3196.0
ME497 Machining Dynamics 2177228