KRISHNA ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

COMPENDIUM OF MST-II (RME-503)

UNIT-I METAL CUTTING

Metal cutting
A metal cutting tool is a tool which is used to remove material from a metal work piece through
the process of shear deformation. Single-point tools are used to remove material by means of
one cutting edge, in shaping, turning, plaining and other similar operations.
Material removal
Machining. Machining is a term used to describe a variety of material removal processes in
which a cutting tool removes unwanted material from a work piece to produce the desired shape.
Machining can also be performed on an existing part, such as a casting or forging.
Cutting fluids
Straight oils. These oils are non-emulsifiable and very useful in machining operations where
they function in undiluted form.
Synthetic fluids. They do not contain mineral oil base or petroleum.
Soluble oils.
Semi-synthetic fluids.
functions of a cutting fluid
The primary functions of cutting fluids in machining are: Lubricating the cutting process
primarily at low cutting speeds. Cooling the work piece primarily at high cutting speeds.
Flushing chips away from the cutting zone.
Rake angle
Rake angle is a parameter used in various cutting and machining processes, describing
the angle of the cutting face relative to the work. There are two rake angles, namely the
back rake angle and side rake angle, both of which help to guide chip flow. There are three
types of rake angles: positive, negative, and zero. 
cutting tool
In the context of machining, a cutting tool or cutter is any tool that is used to remove material
from the work piece by means of shear deformation. Cutting may be accomplished by single-
point or multipoint tool
Relief angle
The angle between the part of the flanks of a cutting tool below the cutting edge and a plane
perpendicular to the base.
Cutting edge angle
Side cutting edge angle lower impact load and effect feed force, back force, and chip thickness.
At the same feed rate, increasing the side cutting edge angle increases the chip contact length and
decreases chip thickness.
Types of cutting tool materials
1. High Carbon Steel tools.
2. High speed steel (H.S.S) General use of HSS is 18-4-1. 18- Tungsten is used to increase
hot hardness and stability. ...
3. Non – ferrous cast alloys. It is an alloy of. Cobalt – 40 to 50%, ...
4. Cemented carbides.
5. Ceramics and sintered oxides.
6. Cermets.
7. Diamond.
8. Cubic Boron Nitride (CBN)

Tool life
The tool life is the duration of actual cutting time after which the tool is no longer usable. There
are many ways of defining the tool life, and the common way of quantifying the end of a tool
life is by a limit on the maximum acceptable flank wear.

End relief angle

End Relief Angle: The angle between the end flank and the line perpendicular to the base of the
tool is called end relief angle.
Clearance angle
clearance angle is The angle between a plane containing the end surface of a cutting tool and a
plane passing through the cutting edge in the direction of cutting motion.
Orthogonal cutting
Orthogonal cutting is a type of metal cutting in which the cutting edge of wedge
shape cutting tool is perpendicular to the direction of tool motion. ... This cutting is also known
as 2D cutting because the force develop during cutting can be plot on a plane or can be represent
by 2D coordinate.
Tool wear
Tool wear describes the gradual failure of cutting tools due to regular operation. It is a
term often associated with tipped tools, tool bits, or drill bits that are used with
machine tools. flank wear in which the portion of the tool in contact with the finished part
erodes.
machinability of a material
The term machinability refers to the ease with which a metal can be cut (machined)
permitting the removal of the material with a satisfactory finish at low cost. ... Other
important factors are operating conditions, cutting tool material and geometry, and
the machining process parameters.
Machinability index
A numerical value that designates the degree of difficulty or ease with which a particular
material can be machined; originally based on turning B1112 steel at 180 feet per minute
(0.9144 meter per second) with a high-speed tool for an index of 100; with replacement
of high-speed steels with carbides in turning.
Tool rake
Rake angle is a parameter used in various cutting and machining processes, describing
the angle of the cutting face relative to the work.POSITIVE RAKE: - A tool has a
positive rake when the face of the cutting tool slopes away from the cutting edge at inner
side.
Nose radius
Surface finish, tool wear, cutting forces, and, particularly, white layer (phase
transformation structures) were evaluated at different machining conditions. Results show
 that large tool nose radii only give finer surface finish, but comparable tool wear
compared to small nose radius tools.
cutting force
Cutting forces are either. v measured in the real machining process, or v predicted in the
machining process design. Cutting forces are measured by means of special device called
tool force dynamometer mounted on the machine tool.
Single point cutting tool
A single-point cutting tool can be used for increasing the size of holes, or boring. Turning
and boring are performed on lathes and boring mills. Multiple-point cutting tools have
two or more cutting edges and include milling cutters, drills, and broaches.
Chip Thickness Ratio.
Let,
t 1= Chip thickness before cutting (uncut chip thickness)

t 2= Chip thickness after cutting

φ= Shear plane angle

α= Back rake angle

r cosα
tan φ=
1−r sin α

Cutting Forces
Here,
FT = Thrust force

FC = Cutting force

F S (Shear force) = FC cos φ−FT sin φ

Fn (Normal shear force) = FC sin φ+F T cosφ

FC (Cutting force) = F S cos φ+F n sin φ

 FT (Thrust force) = Fn cosφ−F S sin φ

Shear strength.

t1
=w×
Area of shear plane sin φ
FS
=τ =
w .t 1 S
sin φ Shear strength of the material

Cutting force with friction and normal friction forces

Here, N= Normal friction force

F= Friction force

β= Friction angle
F=Fc sin φ +FT cos α
N=F C cos α−F T sin α
F
μ=tan B=
N
FT
+ tan α
FC
tan β=
F
1− T . tanα
FC .

Velocity Triangle
Let,
V S = Shear velocity

V C = Chip velocity

V = Velocity of un-cut chip

V VC VS
= =
sin ( 900 −φ+α ) sin φ sin ( 900 −α )
specific cutting power
FC
=
Specific cutting power w .t 1

Ernest and Merchant Theory

cos ( β−α )
FC =F S
cos ( φ+ β−α )
For minimum power consumption.
First analysis:
π
2 φ+ β−α=
2

Second analysis:
−1
2 φ+β−α=cot ( k )
Taylor’s tool life equation.

VT n =C
Here,
V = Cutting speed
T = tool life.

C= machining constant.
n= Tool life exponent (depends only on tool material)
Machinability Index
Vt
= ×100
Machinability Index VS

Here,
V t = Cutting speed of metal for 1 min. tool life
 V s = Cutting speed of standard free-cutting steel for 1 min. tool life

Economics of Machining
D= Diameter of work-piece (mm)

F= Feed rate (mm/rev.)

N= R.P.M

V = Cutting speed (m/min.)

C e= Cost of tool regrind per grind

T i = Idle time (Job loading/Un-loading time)

T C = Tool changing timer per failure

T = Tool life

f = feed

 Machining cost/unit (C 1)
∴ C1 =C m .T m
π DL
=C m .
1000 .f .V
 Idle cost/unit (C 2)
C2 =C m .T i
 Tool changing cost/unit (
C3 )
1−n

π DLV
( n )
= T C ×C m
1000×f . C1/n
 Tool regrinding cost/unit (C 4 )
1−n
n
T m Ce . π DL ( V )
C 4 =C e× =
T 1000×f .C 1/n

 Total cost per unit (C p)

Tm
T =T m+T i + .TC
T
 Rate of production ( Rp )
 1 1
R P= =
T Tm
T m +T i + . TC
T