124 Machining and Machine Tools --------

-
4.2 Generation of Cutting Forces and the Effects of the
Cutting Forces in Machining
4.2.1 Development and Action of Cutting Forces
4.2.1.1 Cutting Forces in Turning and Shaping by a Single-Point Tool /
Cutting Forces in Turn;ng
Figure 4.1 visuali1.cs how rhe single resulranr cutting force R is resolved irllo three compont:nts />x, P anJ p
acting :i..xially (along x-axis), radially (aJongy-axis) and rangenrially (along z-axis), respectively, on th! cut tin~
P;
tool at its tip. :1'e co'.1,pone~us P,;, and /~' shown in Fig. 4.1 are the correspondi ng reaction forces acti ng
on the v,,orkp1ece :ir HS curring point.
ll1e resulram fo rce is resolved as

P1. + Pxy = R = R' = p_' + P'xy

1.
(4.1 J
and
PX + P)' = PX)' -- ·P'XV -- P' + f)'
, X )'
(4 .2)
where th e equation s

pz + pxv = R and P +p = p
. d . x y xy
are assoc iate with the too l, and th e equations

R' = P' + P'

1. X)' and
< P' -- P' + P'
X)' X y

P'y

P'X
◄ ----

Figure 4.1 I Cutting forco components 111. turning.

.
 Mechanics of Machining 125

• d with rhe workpiece. In Eqs. (4.1) and (4.2),

are ~1ssoc1ate
Px = Pxy sin "f/At and Py = Pxy cos "f/At

. •ficant cutting force co1nponents are:

]1e s1gn1
p: It is called the main or major component. It is the largest in magnitude and is used fo r m easuring
1. z
cutting power (P2 V::) consumption.
p: Though relatively small in magnitude, it affects dimensional accuracy and induces vibration.
2, V

3,
p: It is least harmful and hence least significant.
X

Thedevelopment and action of the cutting force in boring is very similar to that in internal turning.

Cutting Forces ;n Shap;ng and Plan;ng

Tue cool-work configuration and interaction at the cutting point are similar in shaping ( the tool reciprocates)
and planing (the job reciprocates). Figure 4.2 shows how the single resultant cutting force R is resolved into
three orthogonal components Px, PY and P2 in the shaping (as well as planing) process.
4.3 Cutting Force Analysis and Estimation
4.3.1 Cutting Force Analysis for Machining by Single-Point Tools
The b asic principle of machining, that is chip formation , is almost the same in all the machining operarior.;
done b y any cutting tool. But the behaviour and role of all single-point cutting tools in turn ing, shaping.
plan ing, slotting, boring, etc. are exactly the same based on the chip-tool configuration as well as the mechd-
n ism a nd mechanics of chip formation.
While m achining any ductile work material using a single-point cutting tool in ideal and stable cond:-
tio n s, smooth , uniform and continuous type chips are formed and come out at a constant speed. Figure -J.;
sch e matically sh ows a turning chip segment at its stage of formation under stable conditions.
The chip segm ent (Fig. 4 . 5) is subjected to the following forces in its equilibrium state:
l. Fro m the workpiece side
kJ/ Sh ear force Ps acting along the shear plane.
(I,) Force P O acting normal to the shear plane.
2. From rhe tool side
(a) Frict io nal force F acting along the rake su rface.
(~ N ormal fo rce N perpendicular to the rake surface .
 - - - - - - - - - - - - - - - - - -- -- - - - -- - - -~M~e~c~h~a~n~ic~s~ o~f~M~a~ch~i~n!!:in gL_~
12~9
1

~,----- Shear plane

Chip

Section A-A

Figure 4.5 I Forces acting on a chip in equilibrium condition.

4.3.2 Analysis of forces under Orthogonal Cutting and Use of Merchant's

Circle Diagram (MCD)
It is already known thar single-point tools remove chips either by orthogonal curring when the chips flow
along the orthogonal plane or by oblique curring when rhe chip flow direction devi,ltes from the orthogonal
plan~. Orthogonal curring is ideal and easier to understand and analyse whereas oblique curring is mostly
applied in industries.

43 2 1
· • • Force Analysis using Merchant's Circle Diagram (MCD)
!~odi:play an~ inter-relationship of the different force components in continuous chip formation under
diagra~ ~~~;tg is very easily visualized and establisheJf 11 by a simple diagram called the Merchant's circle

Const~ •
Uct1on of MCD
In Ortho o
its g naJ curring h h·1 A d
major co ' r e c P ows along the orthogonal plane ;r and th e curring force (resultant) an
th
ti_r ~rnpo:Ponen~s Pz and Pxy remain in that plane. Figure 4. 6°schematically presents the forces and
equJ]'b 1 . nts acting 011 h. . h
TJurn sra Th a c 1P segment coming out from th e shear zone ar a cons tant speed and in t e
te. e for · (. •
ces acting Fig. 4.6) on the chip-segm ent a re
!13~0~~M~a~c~h~in~in~gl_!a~n~d~M~a~ch~i~
ne~ ~
To~o~l~s_ _ _ _ _ _ _ _ _ _ ________________ ____

1.
From the workpiece side: . ion of rhe chip by shearing
(a) p - Shea r fo rce which directly causes separat
, \ to th e shea r plane
(b) p _ Force that acts nurma
11

Herc L\ + Pn = R.
2. from the tool side:
(a) F - Frictional force at the chip tool interface c F
. l h k face and the 1orce
(b) N - Force acnng norma to~ era_e sur '
H ere f + N = R1 (resultant) and Rt = R•

111e resultant force R or R1 can be resolved further as

R = R1 =I\+ Pxy
. f · t'on of the reference plane Jr.R and the
where P is the force component ta ken along t h e l me o mtersec 1
X)"
orthoional plane Jr0 • Thus it clearly appears that
(4.10)
I's+ Pn = R = R1 = F + N = Pz + f>xy
lt is to be noted in Fig. 4.6 that the circles drawn with Rand R 1 as diameter are identical and contain rhe pairs
of the resolved components Ps and Pn , F and N and Pz and Pxy' which are perpendicular to each other.
Those two circles with their contents (Fig. 4.6) when combined into a single circle produce an MCD as
shown in Fig. 4.7. MCD visualizes in it all the forces associated with the mechanics of formation of a machin-
ing chip and also the inter-relationships of those forces.
The significance and important roles of the forces involved in chip formation as displayed in MCD (Fig.
4.7) are:
y Ps - It is the shear force which is mainly responsible for chip-separation from the parent body by
's
shearing and is used to determine the dynamic yield shear strength of the work material under rhe
specific cutting condition.
1/ R - It is the force to be induced into the workpiece at the cutting poirit to provide the forc es
especially P5 which is required for shearing the chip out.

Figure 4.6 I Development of Merchant's circle diagram .

 Mechanics of Machining 131

Figure 4.7 I MCD displaying cutting forces .

3. R1 - le is the res ultant force co be provided chrough th e cu tting edge co ind uce the fo rce R in tht
~ wo rkp iece.
4. .!\' and F - These are the components of R1 and th ey ac t normal and aJong th e rake surf.Ke. The:
/
frictio nal fo rce F and the ratio of F and /V depi ct che na rure and ex ten t of chip-rool in teraccio n. Fl .\'
is the coefficient of apparent fri ction.
_?;- Pz - Ir is the main curring force component used as the index of machinabi liry and for the evaluation
of curring power co nsumpti on.
Y I'Xi - Ir is used fo r rhe determin ari on of PX and Py.
7. P. and P0 - Th ey act through the workpiece.
8. F and N - They act through rh e cool.
9. P and P . - They are usually obtain ed by direct meas urement (ex perim enral) .
l >..~

These fo rces, particu larl y Pl, Pxy' F and /V, are also used while designing rh e machine rno l co mponents and
1he Lurti ng cool and its holders.

4.3 .2.2 Advantages and Limitations of Use of MCD

Advantages of MCD
'/1.r rn.ijo r ad vam.tges of using MCD fo r curring fo rce analy~i s include

7 l'.-a~y, qu iLk and reasona bly acwrarr J e1ermina cion of magn1rud e and direui on of the forct~ (On-
a:-, ntd from rhe known or preJe1nni inrd ·; alues of a few forLt.'>.
v La~y an d qui ck rva lua 1ion of rhe fi-1llowing. wliic. h are used to a~~c \S or indica r--'- the m ac !11ru
d1a1J.Lcai~1ic \ fJf 1he give n tool- wurk rn rnbrnarion .
• h·tI ·in·

(a) f ric1ional furLe.

(b) A pp,uc 111 c..odfi t. ic 1H of' l riu ion fJlL LJn ing J I tht chip roul int ed ~tle.
(c) Yidd .,hea r '> trcng1h o t' 1hr wu1k lllJl t'. 11 a l under ,11 1v lllll l lJ ii L·, 11 I •
, l'l " l ll lon .
J ) ~· , 1v.i 1irH1 ol 1llJ cl 1t 111 J t 11..Jl < >-pr t'nJO m fo 1 d1e Jtfte1e111 fo rL .
t l llll1!'0l1 e nh .
 um;tatfons of MCD
The few limitations of MCD are
l. MCD I-S Val I'd on ly· ror
c orthogonal curti no where all the fo rces are contained in the onhooonal 1
b . . . o p ,,lflt
2. The ratio FIN gives only the apparent (not accua.l) coe_ffi c1ent of fncnon.
3. MCD is appl icable where chip fo rmation is based on s:ngle s~ear_plane theory.. _
4. MC D is appl icable only for smooth , co ntinuous chip forrnano n tn stab le co ndn ton.

4.3.2.3 Method of the Use of MCD

The method and advantages of using i\.tC D for the decermin;i lio n ot d iffere~c force c~ rnponl..'.nts and some rtl.ic
machining features in orthogonal cun ing ha, e hc-i.·n illus1r.11ed J.'i fo lloW'\: Su ppose. m an orthogonal lUrni t<l
a ductile rod of diameter D by a cool of known goomi.:tr,• ( )'.'. ¢. r , etc.) wirh given speed (1\ 0, feed (s ) J.nd dng of
~ . ll ,, Cpth
of cut (t), the magnitude of the rwo cutting fon:t w m p<>ncn t, />, ;i nd P, wn be known by direct measure
MC D helps ro easily derem1inc: rhc y·:tlut:_,. of the il.)llowi ng with out u~ ing mJn y cq u.u ions and ca.lculation.s~tnc
1. Magnitude of the force.·, F. ,\'. P ;rnJ fl .
' r,
2. Apparent coeffi cient of frinion //J .11 the \. hip- tool imcrfucc.
1
.. 3. Yield she3r strength r, of rhc ,H1rk 111.ut·ri.tl J.t that {.utcing condition .
To determine the v.Jues of F. .\'. P.., />., . •LI.l .ind r' with the help of M CD:

1. Draw rhe rool .111d the chip segmenr in the onho~unal pbne Jr l.u<ing the viven ,al ti~ , 1 ., L
. . "- ... u O ~ JI / l,~;l{J'A[.
111 Fig. 4.8 (aL
2. Oerermi ne rhe ya.Jue of P,. from
P = P sin O
' "

I 3.
4.
s.
where rhe ,'31 ues of P~ and Oare given .
Selecr a suita ble :.cale (e.g .. 100 ;--: = l ,m ) for prc~encing P an d /' in cm.
-- t
D raw Pz and I\, .i.long and normal to V_ J) inJica ted in hg. -i.H (b).
Draw che resulcam (R) of PI and P"I.\ .
\, \'

6. Draw r.he circle (,\frrchanr's circle:) ra1cing Rasche J iamcrer [F ig. ~1.8(b)J.
7. Ob tain F and N as inrercep~ br ex ren d ing che rake \urf:.1cc and rhc:n joining rhe np, of F and R~
indicated in f ig. 4.8(c).
8. Divide those inrerceprs F and N by rh e scale and gcr che values of F 3 n<l X .
9. To determine rhe val ue of P, (an d Pn ), th e value of shear angle ~H , is co be c:, al meed from

R cos y0
ran,-,o = ----='--
r1:, -s1ny
.
where 0

[ = a2 = a,
., a1 s0 sin 6

and rhe val ues of Yo, </J and feed s0 are known and i: he chip rhickn es'i a, has co be measured sin~F1:·
by a micrometer or slide calipers. - -
10. Draw i: h e shear plane at an angle /J as show n in Fig. 4 .8(cJ and the n draw the intercepts I's and -'~
0
in the same fig ure. u
 ~---- -- Mechanics f M . .
- - __ ~ach~~- !!~
P-,. y

(a)
(b) (c)

Figure 4.8 / Method of use of MCD.

O brain the value of P5 and P0 in N using rhe scale.

O brain the v~ues o f the fricrion coefficient µa from rh e ratio µa = FIN and friction angle TJ From
ran// = µa or directly from the MCD drawn. _
13. Obtain
. . rh e value
. of the
. · Id s·h ear strengrh -z; o f th e wark matenal
dynamic y1e · rn
· rhe gi·ven cu rring
condmon usmg the simple relation

p_
T =-s (4.11)
s /4
w here As is rhe shear area (Fig. 4.9), given by

~ =_!!f!J_=~
sin /30 sin /30
where t and J~ are given and fio is already known.

4.3.2.4 Development of Mathematica( Expressions for Cutting Forces Using MCD

The magnirude of th e forces F, N, Ps and Pn as well as th e values ofµa and rs in orthogonal curring can
be determined analyrically also from rh e known values of P2 and P,y using some equa tions only (wirhour
rh e direcr use of MCD) . Bur rhese equarions are again derived wirh rh e help of MCD. MCD also helps in
developing m arhemaricaJ expressions for analytical esrimarion of the curring force componenrs Pz and P.._,. in
orrhogonal cu rring.

1. Forces F and N and friction coefficient A= From rhe MCD in Fig. 4.10,

F = Pz sin lvo + PX_I' cos lvo ( ':! .12 )

anJ N= PZ cos r,,O - PXf sin r, 1)

__.... {4 .13)

- /: _
/> ~in y
/ II
+ P cos y\ \' ,. 0
µ ----
J N P, cos y , - /1 sin Y
I \ \ I d
- - --
134
. Machine Tools - ---·
Machintn~~- - · - - ------- ---------

Figure 4.9 I Shear area in orthogonal cutting.

Pi. tan y O + Pxy

ell µ _, = p p (4.14)
"L - xy tany o

2. Forces P and P: i :·u;n che ~"lCD in Fig. 4.10,

s "

Ps = P2. cos /3.o - Pxy sin /3.o (4.15)

and Pn = P2. sin /3.o + Pxy cos /3.o (4.16)

3. Forces PZ and Pxy (and also PX and Py ): It appears froni the MCD in Fig. 4.10 that

pz = R cos ( TJ - V)
lo (4.17)

and PS= R cos (/30 + TJ - Ye) (4.18)

By dividing Pz by Pswe get

p_ = ~cos(11-ro) (4.19)
z cos(/30 + 11 - r O)
Again,.P 5 =As~ where

As= tso [from Eq. (4.11))

sin /30
Thus,

~= tso'l'scos(11- r o) / (4.20
sin /30 cos(/3 + 1]- y
0 O
)<
. . . . le rdacion·
1~is Eq. (4.20) can be simplified for effective use by developing and incorporaung a si~Pu¢inot
ship among /30, T/ and Ya· A few significant angle relationships which are available are disc
 ~ :: f'l-4 f:JcJ-1?; ~;,tf&

/11 : /; ~·11/14 f '),; &,f,f(J

f_i : /IL ~

/J! ~ (f.{.y?,.-,, ,:J/)

7i ; ~ f. ·a /J~
1-S o
2 {',...c.,, l?u - ✓-''>-, .i;;,-rJ;,~
~(o
Figure 4.10 I Development of mathematical expressions of cutting forces using MCD.

Angle Relationship by Ernst and Merchant

Ernst and Merchantfll developed an angle relationship considering rhe minimum energy principle and assum-
ing i; ro be a constant. This approach begins from

d~ =0
d/J0

Then, differentiating Eq. (4.20) w.r.r. fio, ir becomes

cos /3,0 cos o - sin /3,o sin ~ + lJ - Ye) =0
+ 'In - r,)
I R
\fJ'o

or cos c2Po + TJ- r) = o= cos (ffl2)

._,.~✓
Thus,· I,,_.._,.. ,1,'7• 'rt'U
2fio + lJ - Yo = fff 2 = 900 - - ( er (4.21)

Combining Eqs. (4.20) and (4.21) we ger

p = 2ts uor/J,0 (4.22)
2 OS _.--------

. . . J · · ·s nor very useful because T cannot remain unchanged in case of

Th ough rhis is a very simp e equarwn, H 1 . s . I
• an d al so /3, cannot be easily ob rained in case of brmle marena s.
d ucn·1 e marenals O

. h. f31
Modified Merchant's Angle Relat,ons 1P
• 1 char rhe value of r linearly changes under compressive force a as indi-
Ir was assumed for ducri.1e marena s s n
cared in Fig. 4.11. In chis case
-rs = ro + kan (4.23)

From MCD we obtain

Pn =Ps can(/3,o + TJ- r,)
o
 · Tools
136 Machining an~ Machine

(l
ll
= rcocV
"'
l_ + 17 - Y)
l r

. ung
Su)snru . Eq .,,.
, ., 2,-) in Eo·1 . (4.10) ·we get
l:
ts 0 1" 0 cos(ll -Y O )
P= - - - - - -~ ~ - - ~ ~ - - - --
L sin (3 cos(/3u + T1-Y 0)ll- ktan(/3 0 + 71-y .J1
0

• 1 0 tl·l e principle
, ow app lyu
N ·
of minimum energy
O

dPL
- =0
df3o
t0 Eq. (4.26) , we get

. . 2/30 + I) - Y0 = co,- \ (k) = c (say) ----- .c" ; \

14
\vhere c is termed as the machmmg constant. Generally, the value of c depends upon the ty f ,
. d c pe o work mate-
rial. For example, the value o f c 1s aroun 0.7-0.8 ror steels. Now, Eq. (4.26) becomes

P 1. = ts OS
rlcot/3O + tan(c - f3O)1J

A suitable and frequently used angle relationship for ductile work materials has been developed\4\ empbin~
the slip line theory in chip formation. 'The simple expression is ~

/ t~l:)~
Substituting Eq. (4.29) in Eq. (4.20), the expression for P1. becomes

P7.. = ts 0 r(cot/J
S 0
+ 1)

.-=--..-- tan a= k

al stress <\·
Figure 4.11 \ Dependence ot rs on norm
 Mechanics of Machining 137

where
n cosy
ran /J,0 = o
S-sin Yo
and ( is rhe chip- reducrion coefficient. Then

Pz = tso r:( v + I)
J" - tan lo
~ :,
l--" (4.3 1)

(since cos Ya is close to 1.0). Equation (4.3 I) is very important and useful for R&D and in machining
jndusrries -for reliable evaluation of Pz. However, it needs proper assumption of the value of z;. An analytical
esrimarion or evaluation of the exact value of the yield shear srrengrh (-z;) of the work material, particularly
under rhe given machining condition, is not easy. Several attempts have been made to derive suitable relations
for assessment of t; for any work material under a specific machining condition. Some popular equations,
for example, are
r = 0.1 75 BHN -=?Iv" ~'1'' Jlh ri4JJ.., ~ l.t (4.32)
~cw4"'10

V .. (--( e.0~4tr"''"· rs= 0.186 BHN -7 (c,--( r'?t.,..J-,' /,I. rt-Pl· ~(4 .3 3 )
s

/.) r.,, o • ~
"1 f"" = 0.74 CY £o.M _-, fYlv-A,,- /Jaw.~ (4.34)
and t; u _.....- r
. f h k d CY · rhe ultimate tensile strength
where £is rhe curring strain,~ is rhe percentage elonganon o t e wor an u is

of the work material. d /5] c . . d •1e and ductile materials, respectively,

) d (4 33) h ' b 1 propose rot semi- ucn .
Eq uations (4.32 an . a,e d~r d 1 1 used for machining ductile metals. From MCD m
whereas , Eq. (4.34) has been develope an popu ar y
Fig. 4. 10 we have (4.35)
p x~: = P.z ran ( '7 - J;)

. . E (4 35) (4 20) and (4.31) we get

C om 6 mmg qs. · ' · (4.36)
ts0 Ts sin(TJ-Yo)

Thus (4 ..3 7)
p == ts r (( - ran Yo - 1)
X)' 0 S --------

P are derermined from

Then rhe values of Px an d Y . (4 ..38a)
p == Px,· sin¢== tso z;((- ran Yo - 1) sin¢
·' ·, ,-/'
(4.38 6)
J~r == pxy cos¢== tso r,({- ranro - I) cos¢ ---
and
/
• Analysis and Estimation of Forces under Oblique Cutting
44
r !:.een rh.ir in orchogonal curring, the machining chips (if ductile and conrinuous) Row
Jr has already L)ee n . . • . . .
nal plan e ;r. Bur 111 oblique cumng, rhe chzp flow dev1ares from /l'. In orrhoaonal cumna
along the orr 110go _ . <> . . 'J . . . o . ~ . b'
··i r ,J torce to rnpon enrs /: , ~.~ F, N, f. ,ind I remal/1 1/1 Jl' and are concained wirh111 rh e co n-
a 11 l h,: a!:oSU C l, C . .' ·' /I u
cerned M C D a.., ca n bt: \L·en in fig~4. _ JO. Ho wever, in oblique curring, :in addirional force develops ,don 0O rh e
princip;ll c u ccin g edge:. H.:nc,. MU ) 1s nur :1pplic:1blc in rh t' case oFoblique currillg.
 138 Mach1111ng and Machine l C:ols
-•····•----~
1
1·1\)\\'c\'er, j· · h ' \ . t) )I 'l-lll..,lly onl ,v one for({' .IClS on rhe. wn1•k
u1 .my m.1c H11111i y .1 sing e - pllllll l 1 , · '- "
· ··
.., Pttce qt
cmt111l• point .rnd simil.irk only Olh' fo rl.·e develops on the tm)I under both orrhogonal and obliqul' cu .th,
1
Figu,.;44 . l l visualiie~ hm~· the ·si ngle (result.un) force Rin ohliquc cutting is usu.illy resolved irno eith::
1
:s
P ur P which (".ln be derermineJ directl v b,, dvnamomerer me.isurement .rnd are used fu r the design f
1 th
~{.f -T system or I', P and [> , which a;.t, L;seful for the purpn~e of the design and Stress analysis of tho :
• l m n f: J'k a::. ,
.rnd for more accurate t:\'aluation of chip- tool interaction acrors 1 e coem~1ent o ncr1on, ere.
f~• • ' tC¥
'
1r is evident from Fig. 4. 12 thar the vector summation of the measured forces, P~• Pi and P provid~s tt, 1•

,1Ctual magnitude and direction of the resultant single force R: '

:\gain, the same force R is resoh-ed inro :rnorher set of forces in mutual orrhogonal directions, that is
- - -
R = P1+ Pm = Pr\ (4.4(J
where P1 is along the principal cutting edge, Pmis along rhe orthogonal plane and P~ is normal to rhe cunino
edge, that is, along the Zn a.xis (Fig. 4. 12). All these forces are displayed agai n in Fig. 4.13 for convenience oi
analysis and inter-relating the forces.
The resultanr single force R may be considered comprising two components

R= Re +Rr
~,here Re is taken in the curring plane l[cand R, in the reference plane¾· Ir appears from Fig. 4. 13 , the fo rces
m 7r are related as
C

P11 = PL cos A - Ph sin A

and P1 =PzsinA. +PhcosA (4,q21

where P), is an ima~in~ry force taken along the Y0 a,xis acting normal ro the curring edge :md P1 is acting along
the cumng edge. S1milarly, rhe forces in rhe ~ plane (Fig. 4.13) are related as
Pm = PX sin 't'm+ P)' cos 'f/Ai (4.43)

Figure 4.12 I Resolving a single force into Px, PY and Pz and PI' Pm and p n in oblique cuttin g.

I
l
 -
Mechanics of Machin ing139
-----
(4.44)
Jfld . along X (= X ) axis (Fig. 4.13 ). Combining Eqs. (4.41 )- (4.44) che follO\vino expressio
is a.cnng o n o ns
-here Pn1
\V '
d•
a.me.
gre ace P1 = - ?xcosq>cosA. + Pvsin</)cosA + ~sinA (4.45)

( ➔ .46)

Pn = Pxcos</)sinA. -~_sin</)sinA + P,_ cosA (4.47)

and ·
esaid rhree equanons may be com b·me cl an cl expresse d ·in mamx
· 1orm
c as

l
c
. rhe a,or

Again (;m) [-co:i:;os A sinc:::sA si~ ~

= ,l )[

Pn cos</>sinA. - sin¢sinA cos A ~

. (4 48) is very important and is preferably used co determine the magnitude of the fo rces P1, P and
E uanon · m
q~ mthe known or experimentally determ ined va lues of P, , Pv and P1 in case of oblique cutting. Another
pn ro_ n in a similar matrix form may also be derived. if requ ired, by the inversion of Eq. (4 .48) or directly
equano
the determination o f rj1e ,·aJucs ot• P . 11 ,1 11 J P from
- that o~. ?1, P an d P , if known.
[O ena ble . . . \ \ l • . _m . n.
In oblique cutting which 1s more pr.1cuc.1l, the ,1pp,1rent codfic1ent of frJCrion µ~1s co be e\·aluaced from

F' F '/rnspl
,
LI
J
=- =---
.\ ' ,

where P, is chip Row deviarion Jngle fr0m ff. ,· ·1he values of F' anJ ,V' ,1rc> to be evalua ted from Pm and Pn as

F' = Pn <iinv
In
+ P111 co~'/
/ n
('-!. 50)

3nd _\' ' = P 1 LU'/1 - /Jm sin I1/n (4 .5 1)

Figure 4.13 I Resolved components of the cuttin g fo rce in obl ique cutting .
 -
'.'"'::'"t---
---~
y

•
170 Machining and Machine ~ool~ ________ _
---- ---- - -- -

4. 9 Solved Problems

During pure orthogo nal rurning of a mecaJ rod by a too l of the following geom.et .
=0, onhooonal
i:,
r~1ke (r,) =0 and prindpa/ cutting edge angle (¢) == 90° - it was nry -dJnclination ,
" • . o re th an,
of rbc: tangential componen t (P)·i and rhe axial component (P) x
of the cutri·ng f'Orce at the"'.,,a_,,n,f : ,
N, respectively, and rhe val ue of chip-reduction coefficient (() is 1.732. Using MC are 60o i'.; :n;,';
d iagram) , determ in e the magnirude of the shear force P~and the frictional force Fr,
1 ab
.or tie
°
(Merchant' · ,'
sc,:
. . . . . ove cond· .
Solution: G ive n rhat Y,O = 0, ¢ = 90°, P.Z = GOON, PX == 200 N. Now .
ir.,,

j) 200
P =-x =--==200N
xy sin 0 sin 90°
The scale is chosen as 200 N = 1 cm
·n1en,

600 200
P =-=3cm and
== - = 1cm
z 200 ~Y
200
Now, with r,. = 0° P - 3 cm d p I h M h ,
o , i - - an xy = cm , t e ere ants circle is drawn as· •
MCD, friction force, F = p = I cm and shear force P 1· I h h I in Fig. 4.49. Frond
xy s s a ong t e s ear p ane. We know rhar

cosy0
tan/J. =
0 s-sinyo
Sin ce v - 0°
'o - an d ~,r= I .732 (given) we get
1
tanp0 =- ⇒ P. =30o
l. 732 Po

Figure 4.49
 Mechanics of Machining 171

. cept along rhe shea r plane,

rhe ,nrer
from
Ps = 2 cm = 2 x 200 N

r he desired values are F= 2 00 N and Ps = 400 N.

'Jhererore, t

PROBLEM 2
X/hile rurning a metal rod of diameter 100 mm at speed of 625 rpm, feed of 0.4 mm/rev and 5 mm
~e th of cut by a carbide tool of geometry 0 °, - 12°, 6 ° , 6 ° , 30°, 60° , 0 (mm), the following observations
p made· Tangential force (P) = 1200 N , axial force (P ) = 400 N and chip thickness (a 2 ) = 1.0 mm
were · z x •
Determine the yield shear strength ( ~) of the work material under che aforesaid condition.

Solution: Since A= 0 , it is orthogonal cutting. It is given chat P2 = 1200 N , t = 5 .0 mm , s0 = 0.4

mm/rev, Yo= -12° and a2 = 1.0 mm. We know chat

Pz = tso , s ( ~I' - can lvo + l )

1200=5x0.4x ~((+can 12° + 1)

Chip-reduction coefficient

S= a2 = az
a1 s0 sin(/)
Since ¢ = 60° (given),

1
(;; = - - - - = 2.886
0 .4 x-s in60 °
Therefore,

1200 = 2 x rs (2 .886 + 0.212 + 1)

Hence,

1200
T5 = - -- = 14 6.4 MPa
2 X 4.098

PROBLEM 3

In an onho I . . . . . c
co gon 3 turning by a mol hav in g r,. = 0 ° and ¢ = 90 ° , rh e m ag111mJes ot the c umng rorce
ap rnponenrs pl .:rn d JJx were cro und co be 800o N and 4 00 N, res pec n. ve lv. D ecernun.
e rn' e v:i Iu e o f me
'
parent
cond· .
coeffi f . ' ·
icienr o frict ion (p) chat will occur a r rhe chip-rool interface und e r rhe abov e-m e n n one d
·
· ltton. a

Solution: [r is Orth ogo nal mering, therefore MCD is va lid . Sin ce¢ = 90 ° and Px = ?xy si n e?, we bcr

Pxy = P'.\ = 400 N

 172

= =

I, '·Ijl:!1I

Solntion: ~~...:~ - -
- .-
- I ._:, ~ -
--- ..... __ ... __
------ . :_ _

- 1•

1 -
=
=

= = -----

'•. =

..)

.J
 .. 0.80
'- = - - - :::: 2 886
· 0 .32sin G0° ·

n,r1t'!,1rt'.
cos(- 12°)
i\
0
ran ~ = 2.8686- sin (- 12°) = ·3 16
0

Ps = P2. cos Pao - Pxy sin Pao

⇒ Ps= 1000 cos(l 7. 53°) - 400 sin (l 7. 53°) = 830 N

Pn = Pz sin Pao + Pxy cosf.l

Po

⇒ P11 = 1000 sin(1 7 .53°) + 400 cos(l 7 .5 3°) = 682 N

,. 11,,·minr r ,1.nd cutting power consumption: W e know that
,tl I ( < S

Pz = ts o rs(':,I' - tan lvo + l )

Therefore,

1000
=----------
4 X 0. 32(2.886 + tan 12° + 1)

1000
=- - - - - - = 190.6 MPa
1.28(3 .886 + 2 125)

Cmring power co nsumption P..:. is eval uated from ,

PC =PZ VC +PV
X t
.
1.·suallv P1 < P1 and feed velociry Vr «\/, . Th us /\ \If is neglected. 1herefo re Pc== P.l Ve N m/min. H ere,
,:,uing vclocity,
nDN
\' = - - m/ mm
C } 000
I '
,ti,given that D = 150 mm :ind N= 500 rp m . Then,

_ _J
Tr X 150 X 500 _
V = - ----=2.15.)m/mm
C 1000
lhtrtfrirr . '
,cutungpower J> = 1000 x 21';.', N 111 / mi n = :) .l) 25 k\X'.
 · e Tools _ _ _ _ _ _ _ _ _ _ _ __ _ __
t11..r::!_-
174 Machini ng and M~
- - - -
. d f p expected to develop while turning a d .
.
I , rn agn1ru e o .,_ o . Uctde .
Analytil-,lllf es rnnac e r
i t: . r b a cool of A, = 00, Yo= - 10 usmg the followin tad at fe
mm/re\' .ind 3 rnrn deprh of cu y g conditiol) ecJ ~f r
rs = ro + Kern ~: i,

r = 400 N/mm 2 (MPa)

0

2/Jo+ r;- Yo= cot- 1(.K)

K= 0.18 and(= 2.5

Solution: Merch ant's second solution is given by

Pz = tsO ro [tan(C- /3,)

O
+ cot/3,)]
0

· given
Ir 1s · h t - 3 .o mm , so -- O· 20 mm/rev, K= 0.18, (= 2.5 and
t at -
Ya =-10°.
C= cot- 1 (K) = cot- (0.18) = 80°
1

an d cor/3
0
= (- tanYo = 2.5 - tan(-10 °) = 2 .67 6
or /30 = 20.5 °
Therefore,
Pz = 3 x 0.2 X 400[tan(80° - 20.5°) + 2 .676] = 1058 N

When measured by a dynamometer, P2 and PY were found to be 400 N and 160 N , respectively, in plO:
milling by a straight-fluted slab milling cutter of diameter 100 mm at speed of 224 rpm and deprh of:;
mm. Determine rhe values of maximum torque that will act on the milling arbour and the correspond:::
power consumption. Assume single-tooth engagement.
1

Solution: We know rhar the power component or the tangential component of the cutting force in r -

milling is obtained from the measured values of Pz an d Py using

PT = PZ cos 11r.
'f' I
+ Py sin 'f'1
/4 _

where ~ is rhe angle of engagement. From Fig. 4 .50,

D/2-d 2d
cos</) . = - - - = l - -
1 D/2 D

fr is given rh a t d = 25 mm and D = I 00 mm . H ence

2 X 25
cos¢,= l - - - = 0.5
100