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    60 views79 pages

    Metal Cutting PDF

    Uploaded by

    Mohit Prakash Mishra

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 79
    is plastfealt deformed sith the help of a mc tool and a cutting toof ad memovel oferta) takes place tn the form of a chip. MACHINE TOOL * A mle tool ts an assembly of severa) ait{erent elements, machanismns » psime mover as well ac cpu (micro processor (optiond) wohfch holds beth w.r ¥ colting Test in an appropriate poston and ean athe mapotred welabfue moments bla the wand ¢-Toel, CUTTING Toot » cotting fool ts the one which comes in civec| eantact of We “> to deform if plastteally-- The cing joel molerfal must be at least 40°], harder than the uf. material, . single point ra Tool LsPcT) " ny orale. ody ous one as edge eames tn contact watth vaoee piece « Gxamnple! + Turning + Pacing 4 parting. »grovetg hace eating 5 shaping * planning geo Tost, costing Teo} Geometry ofa single point St Tool, ay Had yes We am ay pmosphet surfact oP During ge surface Betas heen Rnctpol esting ectge ond 2 side culling edge [afer cov ee] e ace 0-2 End coblteg edge | itor outling edge [Avxiliong cutting edge. Fy! TOOL \W HAND SYSTEM + Tip of tool ip never made as shasp cssner” yt hays gun ecertatn vadtos of corvafyre called Yose vadiys. se that the Stress a’ propagated and prematore fatlure of +p of ooh 1% evoteled. to provision ef Nose wadtys some portion, ct, Ere cxtting edge Sn eonfatt with wp thesegre UH is also called ax 299999999999 9999998F9998 OESESSESESSESEESSIEIIESIEYV L To PuINGill the above conditions the three surfaces (viz. RaKeFace, End Plone £ stde Flank) ase grinded and sloped. s0 tha} rotal stx a appea® te define the deol. s ushen Prese sfx anges and sioce vadivs Ctotal Feomement) ave written fy a pre deFined| sequence Men tt & called as Toot signature ® Different types of Toof Sc 4, ASA TOOL SIGNATURE * Proposed by Amerteon standa berence system. on Machine uferenst Seana rq assockabtn ond th i Based ° mea ¢ 10 — 25 2” n, Back Rape. | Enea ling Nose Radtus angle a, Ord Reliel aia ng ) nog th) “4 e Side Rake side Relief? side colhing ag angte (es) gle 6) Angle (fs) Bicicn 89 fo co .N s RaKE RELIEF COTTNG Machine REFERENCE SYSTEM, / Tx — LONGITUDINAL. PLANE Fy is pespenditevbr to Boye flength of txt. Ky ts paral) 40 vsfalth of tock. Ty > TRANSVERSE PLANE Ty fs pewpendfenlas te Base € ustdth of, the Tort, Fy is favalle] 40 length of tecl. 9222999999 29999 99999999 CL stnee, the ihe of aL Ant Hee suvfacas Le., Rake ae side flank and end Flenk ave measured use} and Ip tne planes of mle eahich Fx, By 4 Ae. therefore ASA Gen is safd to be based on cle Reference Sam SCE SHEHSSLEFELESEESSETSIONY a Xe Te om 2 Xs Re Ty. % i 7 Xs Ty x Me x Re Ye ry ma Bs £8. ES. gree Revie CUTTING WATE Re CAA) IN! inverse 2. ORS TOOL SIGNATURE * ors stands for or hoger) Rake sysko Which Uw based on Tel me ference an ig ee Fy 5 —T X ose radive nek sree ange 39 ee H e 9999929992999 99999998 Tool Reference system : ASA Planes mle Reference pea Dorin mle forces appear etther along. the cutting edge o% perpencticolar fo the ey edge put tn ASA syskm there ts no plones which ts efther oleng ae eabting 2dge perpendicolae fo cutting adee | « Rr Feree analysis there most be a sytem fo which the planes are ateng. Pre jcchitng. edge and pexpendtcolor to een adge. FSS SSEEEEE to such s SH) + : esting : Exactly clone: Sai re aaa plone : pespendicolor or ede. INCLINATION ANGLE! eevee esserrrr2g9rrre tana, = Sind tana, + CosA tam Xp A when Az 90-Ns ! anol = C4 Ye tou Xs + sin yy ton Xe —A BOAD = SOAR Tt S0BD PxoDxAG ~ 4308104 + bxoBxoD cs ODKOASINA = 1 xopyoncosA + Lxopxod 4” onxok OD Divito bolt, cle br sind copA,t ad op «Op OA sind _ cohA , I Ted, Toots Tot i Lean 7, = sindtanxe ~ COLA bande put 9 A= 90° Ye [tant = cos 4, tan %g- Sine tam oe| GPP PFPFFFPFFPHPAAAP OKO MP HM aAew tan t= COsY, taney — Sinton Xe Ceti kan ats ~ cobiy, tan XZ Siny, keV ote H WEDGE ANALYSIS OF SINGLE POINT CUTTING Took The augit made ww the face aud Flank of Tool 4s called as eoedlge ougit os tp amate te) FESSSLELLE % veo’ is wedge angle Shogth of cubing alge tneveat a vahtle chaxpness [Keenness dporeates and vice-versa, sedge agte (6) shangih sh cotTig age ; te 7 mae ae oe Shavpness of hy ealge e woulge angle co) % _1 pao Rake eri (te) . Positive RAKE TOOL © +The Rake face te beled Me seherencd plane sloped to Aowonesard aLtrect fon, . Reratively, Ness Race and power appears during ca athe setop lacks tgs. + Used to rfe sobt, dvctile £ too shength molertals. . Gesealty the fool ts made vp t, dish speed steel, + NEGATIVE RAKE ANGLE PIP PPP PP RPPPP PETIA P ELE P2994) Iai nian ras fase ae ~ [NOTE] Eventhough a Negative Rake foo} is capable of mle Very hard oud sheng amalerfal if can nof be used to me two shength and soft moferta} because oat the Mle of tow sbergth | soft and ducttle matertall *he chip peel ceo neu! and tw tong Ron. Pace of ve Rake test esl oe the blow of these ae sun ehtps Feesonds sen Carr befuseen end flank, aud mle sufatt) lead ry. ty sever” wee | aud detertoraled peace Rnish- Shere fose using & patvoe wate tool te moat eohveh wath ete goitle fre fon op ehp cvseg For mle woe The -ve ROkE +ZERG RAE TOOL: + The Rater dec ol} jeo\ + Used fos manvfochor'y « vsed dosing. me of «TE hod th cduantage ond timdtobtne bho ave £-ve eke tool. emis +\h ante + clearence angte +90 catrefaes vatth ee! plane. of simple Roe Font, fade tre Baars » cast ron, Sees TS OSSEEHELECE SEES NORMAL RAKE SYSTEM + [15 %n oYeny Yen y Yon, +N Comm) Re AK aps he +The baste ctittesena tn ors aud URS fo the ach trot In ors, Rake amate Co) amd clerance ovgle Ue) are visualized in or thogona) plant. where ar th NRE these angles nemed Movmot Ralce Angte (tn) ond clearence auate (en) anc} are Wovadbeed th novmok plone (An), SFPPSHFPFFVIPPPOLSWIVWIW®PHSVIFPFP29H congersen formula CoRS —— NRS) tan Xp = tan% cost cot Yen = cat Yoo A + The pexpendicvlor aistance blu ctmospheric suctece and machines! suvfacr ts cated at Debtp of cot (). 23 ~y “> 9 “= «J =) ad 5 The tength of fortton t mmatn a edge whieh Fyemotns w contact oth vst doting ts ming is called os wield Ay S088 coate oinA = aw ES $ Re enperiences| Bp the pata edge in ‘ks perpendte vlan © ie. ° Atrectfon Ww called os Uncut totcknean Ch) oR TRIE FEED, offve, movement ru cutting. Too] f esork piece Sea reotie ts called ar feed cf) i www o-™D,. a wocut ea seolome 4. Uncut Hnicleness LE oneal teugth In BORE cosy, = sind = ‘8 e & BA ian, (Eo ane =~ ~— = and . = if W-0 ie, azs0 then, (G24) ~ § Far the. stintlon cebth ct cut the toot eofth tanger SCER value results the SceR the cotdth Ineweates Ao lesa votdth. te, by, erensing for a constant depth oud vice versa . i Meso wth force 4 power Core re a Oy 4 sc€A valve 4 force t but fh %s necessary. to give scen to the doe as Helps guflle the flo ef chip 7 fom mle the value sf seen ts Umtled do a mapimurn of 35° must be above 55”. SIP P P9997 T2772 MP POAC Question: Perna torning- a we at a fed sf 0.25 oa wtth a teat hautha back wack angle and atte voke angle 4 wespectively. amd: uncat thickness of 0-25; cea ebtacred. And tretthatien omghe od orthogonoh woke ange A cosy, = tt —e Y<0 f A=30 § Ke Re Angle | wet | IW K. ie = a KR iN ie R | ‘ Xe Re Ry on Re we : = ‘ oe, Re, Ro t e Xs Re Rx (ae SE | 2 he “= Y - POaieo, Ar . . ° oe Re pee Ny, ; 212 oy 7 XS Benes — th = O08 Ys dan ety - Sin tom Ms tansy ~ Sinton %s | # formation of chips % Ductile matervals : CPtespenanie model of chip formatfon) sharpane 6 Dorin the mle 4 soft and ctocttle matertol as sco as the work piec2 comes UW) eomlact with ea onkge ef tect, Compressive shea ena Ww dhe 0. moteriad ‘st ahead of Soa odge . Now os Yue ae of wns comprestive Shesp inerare, sheas sheae obbeass in tad zone in APfereot ctivectone and ty atfterent mognijods ancl ag Nae of theke shsas sdveabed also Mroreassr. ee Kit ont one sf tose Liechond , ee ot shear stress a ae ak a s ruateriap. heed + soaris. * at dae “upon procesp gaxawrelers) befing in thof plone calls % hh a son ci Wap ves ty PPFPIPPLIFP PPPS PH S2IMFP LLP PP Parcel © The angte made blo ety vetoctty Vector and the cheat plane “ts oatled ob shear ung ca. + The welative velocity of ea Weel rt the OOP called ab cut velocity. We AON HM|mIn, VW 20N ; : {ood "Ymin Y= AON ml, Loon X60 VeRDN Y 2 SS \ ‘ Med os RP Th wetative urloetty ef chip wert the ool te calles chip velocity. (Ve). chip wort Ane wf. ts called o& shun velesh (a) +The welative velocity of dhe shear plone and aa velocity were + The ounghe mado bw Vs cated as shear ougte chy \ eae cosCh-ee) Sing COX 6 . Chip aaa . x CUTTING RATIO chip thickness chip Reduch on Ralfo Ratio. he bet fe Bs pA ty u te, t, ea greater thant, PPPFPPPPHFPIIAAS OTE RE y= cot & + tan Co-% fey sheor stress to be wilntnurn + pbSbRTTOSU a a — eonee> + gac® (hm) 20 cogec®d = sec?(g-x) Sind = cod Ch-%) go-g= &-% 2h - Xo 90 Quest what voell be We watn, sheaf undes gene by chip ot one worth a tort hau tng em rake awgle - 12 Method: th =o Y= col 4 + tang A ‘ Ness Bad + stent 2°4 Method: Y= cot & 4 tang ay ~ ~ ensee? p eek deo a ewsec? b « S204 Sing = cong oe eae Vendy > Oe 4 4 an CQ-%) i Yuin = cat 46 4 tomliso) Nene ar Method : = ast oe a Es © 245° = aste 4s LY =< ahd atom (eG) = 2. Guat. And min. sheow shrath ontergont ba htp fore mle wath tool having. 6° Rate augte. i ; + aS tan (42-6) * SHEAR STRAIN RATE CY): Bye ke Nbc 43 € time aL y 2 4S/ Y= oS/on 1, Eas © _ ~ » ~ 8 "2 t y. N Moy f H\njer- velahion between ty £ tr. ax “2 GC 2 Thickness of Peimavy shear zone U (84) Pe chip tntckness wot : _ Se, eG cont) eevee ae COB (P~%e) es b copa. ging Sings seeobehe » 4 Sinks tan > Rear menbds i te wsined PePPPPPPRPSPFIIZEVISCO ~ ~» vnevt volume = chip volorne, [sur = BER] —e Lom © £6: chip thickness sotto y % FORMATION OF CHIPS IN BRITTLE MATERIALS ~ Bere etl time time MRR = WEN = Wt Ne MRR = WEN Sdv = wtave |——®) " a) =) “= 9 Propa tion of Dace rmajeriol crack develops in vo-P. molerto® eee “Im cone ef Belle modertal he chips art of frregular shape Pog whee. + Bot in cose of pucltke mofertalr volich ia shrath hardenable Ais contin vue ahitps 4 Regolaw shape ond size B Remed Cif eanditons are favovratle). # favourable conctt fons Rr continuous chips : + soft and Buettle voork pieca matertall * Large peer tool (tow wedging action) High coting sped of sheas itlating. ornate rack bepag.ation} + Simat) Red aud oleph vf cut { fomohes oi sno + Presence 4 colting Fro which gee bolh aT and lubricating ashton, + Pvourable condiitin fr dtecaninovys chips: sHord { erittle wo? mateo, uot ‘ fake ‘tosh. PIVPP PPP P9999 9299999999999 08 eF) P » Continuous chip estth Bullt- op edge ! Ee BUE FORMATION BvE size Re 6 BEGINS REARS. ; {WW FRAGMENTS BUE FORMATION RESTARTS eer ce tition! docttle material lange avnsonk of heat geste tm Ma wfc zone cool th vy high deme, of the tnferfaca sf cutting edge ond tO? MY Anis nigh dump Wa to veu clean sorfacss of metale aYheston stast: leealty. be, wa malertol staats to adhere lee A sorta. of the cag edge Ley B06 frmnatlon ah a mie. the see af ave 4 ae sess seebesevereedsg | Bos ie Rake face ocevrs rebutting Mfo wear ab tna foc. while Rest e brogeents ploogle geo Ane Ptonke and mle surface. Rervl into hea sven” detertorotes| surfacn finich, ‘: oe . , ly the begins echen) the Bue forms, fh protects Ane cutting ectge aud hence Ma fermalitn of BOE fm proves tna ded Ae but oy Th breaks Fragmente Hun aesotts Tn ee wear at both Planks surfact and Rake face a eed ay oleterigrates Hu surfact Finth, Pe Gralie conde) hh. auc. Qemiohtie + soft amd stuck le we matertal + medium SS speed + medium feed ond cle pth of cot. + smatt Rake oof + Inso fFictence or fal absence t ratios Awd, ae ef BUE can be ce Hiteed' Jab : FIPPPSLIFPFF9P PPL PPP 977F29P 9992 4 8 ae spect feo] materia) such a cexemict} cermuty dy Qua, The tool a ot oe single point seight handed ee oo] ts provided In The vethogOnal wake See core). the sum of the principal trojor) coting. ode oft ort ‘ cvrttony trina) coting alg onglt of the oboe fed & 9 The Inctinalton angles eh the princtp ol ond he ae ei odge awe both 8. The yonctpal aud ooniliongs onthonenal clearames amatas ase woud @ weafecHoely The wake ae Cn Srp) meagsored on tht outhogere. plene ts 5 0 me os, Y to te Ke ("| \ A+¥e0 = 90 Po AT Bt Voge (80 p90 SSCS SE IISEL e blo bob cxticgege oy se the the og sft Fe ont alte perpen other: ditcolna fo each pce ace ts ZERO, ' nits * ORTHOGONAL 4 SBLIQUE CUTTING : 4 mle iP freax ape dwo Cee Hen the ele cperalfon 3 colud a Se ae exiting operon, Example ! Saving A Brea 4 prin, of very thin pipe , a mio th forces oppeot” Hoes Ginvansionaly. then Ane mle operation is catted ca oplique culting operation, Exomple Except the above thyee operation Nea OR Brcgshing 4 sar +t art Hin pipe ab ths ober oparatfons ave cntegorised undor oblique cotting. conversion | ORTHOGOWAL TURNING Z OBLIQUE TURNING Zz + [ese = Faas ‘ Be 3- dimensional Ge Jongituciinal enmyonent of cotting| ae a a PIVVPPPHLPSFEVPP PPP HHSIFR9IPPWMP PROF Ft Thrust 1" Foxce. Feed Force , Fy = Fy C08 Ne = Fy SIDA Rocio) farce, Faz Fy Sintfa> Prove Theost free, f= TEEPE fF Y=8 or A= 90" + Feed force = Twrust force + Radto} force = 0 SSIS SSECLETEEELETCES TIED Allowing. Zones. # FORCE ANALYSIS OF ORTHOGONAL CUTTING During. mic the Seles ast aot consumed info tre Primary shear zone :1n rien asround 704, to 801 ts consumed because i * Due to 3-D force Sys: the force analyci of oblique cutting operat? become dify F hence all the oblique eotttns opecalion art treated 04 Ca (2-0) byte Plowing axsumphions ! sthe ce te Ite oe velocily vercto C0), A continvous chip farm without Bve. *The CE ts Shafght line & entendad, beyond width of cut: «the c€ is pesfectly sharp and there 6 No contact along Plank surface. + The chip dow not Flow fo either sid TAN proceds parameters yematlns constant. smost of the heod 9s carried ea entp Feltased % Tool 4 wsovte pipe- A . pretribotfon of heat es chtp 1 toa £ usp is 40:20:40, g | Stoce, enegy ts actoall comumed thle Hae aboue tue cones only Hherefore the forces will actually appear’ th}o these 49 zones aa eahich are ox Follows ¢ (A) IN: PRIMARY SHEAR ZONE ! 4. Shear force (fs)! This Bree appears into dhe sheang plane due fo verubanee of oP Cone Secu 2, Normal te shear (Ne): This Bree acts tha direction to the princtpa) shess & ts algo called ay Backup force, V=EADN . & oo Cas o e e & o~ o oo Perpenctfeolar to the shear plane due o | 6 vw. T — shear Bro of we moferial, than, shear Rrce, Fo = Tod (8) AT TOOL: CHIP INTERFACE : 3. Fiction Rrce CF): Ths force acts at the underside of chtp info the opposite clivectlon of chip morrement- A, Normo) force CN): This Gece acts at ane chip In a dtveckion perpendiiculor do wake face due to chip's momentum at wake fact. Fotetitn frce . F= HN cpege. of frichon , wetenp = (B= Frickion orate) KRONENBERG'S ANALYSIS : 7 + lef us consder, @ chip ebment of lor deepl tde? mass tm? which Pa a ci jplocoment ‘le th the Lime ‘dt? As tt undlerqors & displacement to ib veloctiy a pom v to Xe. POL PP IPP PP LPP 999997908 tiny] = -+ (el? ee | met - Cel InNe-InV = -# te -~.) Invetnve = BLE) l¥~ RLE-Xe) ois HR) « The above fur frees Reich ote Cid eigen only. actual farces but these Perces can mot be yncas! as Wey apreav in Aymarnit eodthtsn onl actvod forces ot first Feces acting. on the aoa aoc) & Horizentol avrections cwahich ave G& and ; ssa i wah he help a see. chivectt ie woe mensore We + Merchant sane brought A these Loxces at the tool tip £ forresd & them Head 40 Tail which ruolted ~~ ho a aikcte named merchant's exfele offer him, SS y wn since, 1+0 M%o= Xr Draw mmexchoul's circle ay wk with zevo wake toot £ note down the ai fherent observattone PIPLPPIFPPPHPHLPPPFF9P97299 22 2e X Dears meychant eixcle Ry mle wlth a -ve Roke teal, f. 208+ EF = AFT AE [rice Fecanh + Ne sing £, = Be = CE-BE > CE-AT vi + fe 7 OB= GH= DHt Gd Bese f.-0A= oe - AE =0E-BF ‘s Fee 08 §- F, sing Neo ac= cet AF New Feaege Feng FRICTION FORCE | F= op=Pd+ OP = cg+OP Ee F, COA %o +t Fe Sin%s| N=cD=P@= PB- OB + ln merchant's civele there ase three right omg Aviongle VIZ, BOAC, owe and Bocn. having a commen inypetenovs ree) which is equal to 'R and {YU also te diameter of merchant's etrcle. R= [Rey = J RoeNe = le in 0 OAC pe 2 Reo COTE) we = RSID carte y- Ne ad as et. “2 md in 8 08C “= ~ Fe = Reds CB-X9) in gocpd ‘ oad Rain CBX) tan (B-%8) * & # Normol shes fo shear on chip, - = (Fe Sind + F,cop &, x (es im %), sind yt # ERNST AND MERCHANT'S THEOREM FOR MINIMUM ENERY CONSUMPT, +s theorem ts help Fol in expotetishing the postilon ef shear plane “no daformaticn Boas by oasoming that the chear plant U located cohere leat energy sequired, Ascom tion | Orthogonal cutting ° ' lane 2 sheqs strengh of materia = ‘eae ts not abhected by nes mol chess 3. Continues chips form usttheut BUE 4 Energy ef chip separation & nestected, Fae ROM CHAR) nia ~ Cy eh COA CB - oko) SPSS) a) foo, P= FeRN Pe ran COA (B-Xe) ag CO Co+p-%0) ps Ts WH cop xe) ny SIN conch+pnx) ~~ * ) “9 ~~ ~ ~~ e a ae power” do be minimum the denominator stho. Cop Ch -+p-ofe) must be mayimom, a sthh. cos (o+B-%) = 9 +e Coad. OSCHTB-%Xe) ~ Sing Shh (H+B- a) 0 CO CO + P-Xo)= 0 — BRAHMASTRA Qa, Derin ory process wth Yok 6 6-6-30- Sloe RPM sei iene merteborr te cap nce DSc acai Breese ep ee of) ent osed. The side yore of the toof was a choosen that the mo opt ration cousd be oppronimated te be Ve eutting . The fea cuttin fore ond foust force wert 177 u aud sco vubectively. cafeuleti U) The sicle rake angle (iy co. epg rctent of frictcon af the ralee face (wy The Sei shear shength of the work moferal Sof" Oxthegere! or) ,2=0 tani s cos tamde - Sin ton as 0 = COS30 tanz- singe tanas Pace \n B OBC tan (p-%) = Fr iu F. c Be tad ()+. pe tal lea al Be 39.23 Coch. of Frichton 5 He tome = tan 3903 = 0.@2 . eins mn. envrqy eens ptlorn 2h Apolo: 40" > « Sox Xo7F _ 90413-99- 29.23 = re. pS SISSIES b= 08 Fe , FCOSb-F sind CCI sie ge eee se Ten Ota shear Shess, Ts a 5; xsinb 43. 42 fa Qva, Dorin: tomy a casben slee} aod of 160mm cllameder Py carbide too] of gomuhy 3 0.04 £0 18 415,35, 0mm) of speed dh) &00 2pm 4 feed of 0.32 mmbeu ond 4,0 mm “debi sf cof, tne ue observadton wert made, Sy com ponent of fa a irce, R= l200N Avia) component t Ein Foret 1 fe: 860N Chip thickness Coffer eat) , X= 0:6 rm. Perepreerase z(t the above case coudtion delermine Ate value On : : W Frichlon force fF aud Mormol Gece oe the chi¢ Foo} interface, _ W) Yretd sheaw shength of tee worle material onder shic 3 mye eon dt} on, (wy ig power” consumbHen ‘hm kW. here A=F5 YWoxlS = faulty) > taal (38) = 123 re + the Pirst solubfon a merchent fe chaos omg & Br minimom energy emsom pon rd + Merchant found this relation “ assuming, thot there Us nv effect of wosmo) ehess ‘6p’ on the sheae sfrecs (Te), this resold cf wurchant oggreest wool wth eppesimentel YAULH obbatied vobile me syrtnelic plaatte bu} dhe etal dn agreed poorly, vanlle mic of shee) with shyfered Canbide. Now, merchant sence sie forthor ang assume tak the Show sharp 1%) would ve hftuenced Atreclly by neweal Shess on He shear plone AS Pallauas, TAN Ts = TT KE Gt B20 § T= To a Ts SHEAR STRESS CHANT'S SECOND SOLUTION NORMAL STRESS Op SO, T= Te- KTe tan(h+p-%) | el. \ tontere-*0)) a | Tet /recton C4 p-40) ee reeset ntcn ay Pe Fax C04 (Be %), cor Coap-%) my. voby Ne COB CB) Senne Cyne COs CREED fie sing .c0s Cpe pee) gio, pens) SS) Tk kan (pape) Stns COAL IP) SPSS ETTIEELIEEE aero rah eshole term Ph wrt. “O! od equating qo ZeXD, —=0 —= | 2o+B-% = cot Ck) = Cm Merchant's second solufion, ‘ef total of 2g 4p-x%0 = Cm = cn4"(K) bs eatled NG CONSTANT. PARTE TE cry = cotl(k) <90 4 then, Ke eve ti ae ° the inference ts machin A. csi bie case’! = ff Gye col’ tk) 7905 then, K= Ve te Fee] the frfirence B machining ts not fossible, : SUMMARY! of ¥ , Geo eccre co = Nye fe = min. energy cons ompf , Cm < 90° = Te >To Nyy < 108 fe mle possible CmF90° — Te ST —> > I00 oh. ele not possible eres e + During mio the asp total energy % consomed eftherr in shear” zone or at deo} chip interface. 220 P OP PROS PRP? So TOTAL CUTTING ENERGY > ENENY coUsumnp" [snesaing+raietion] e. Fol Ve t OX Ve Siti) Mariel) or -8 + ¢ ENERGY 1 TK the valid bio Respective onary + specific Peg peessore | a ale, (es fry cote as ; speci fic sheat energy: Sent a in «specific Fiction eneray : ‘ w Papa Ra ere LX 5mm? DY ety fet ecHonol Ressore | + spectPte frichion alt Meee ie wk, + Toto) specie alc ener gy | mUrnk Ost Ur FX Fsxe | FRC = +a wh Vy OE, WEN CHINABILITY : pose unth which a re operation Wi. Tool Ute is move. nN. Surface fintsh ws move Ne Dis eonnvovr chip w fosmed. ® MachinapiLity INDEX * ‘t te the vahto bla the 8 speeds of, the test wep, and the standard wp. Crree eas stee}) which can be achieved Rr a 60 minvte Tool life. o- se cote ste can achieved agprovimaely 20 man ed fix 60 rein. fod UiRe. iether coin. spe steal machina | + ttng Se, Si, Se, Cal, Ph with zero rake Too} “ preove aD tos. (Fe[rty) a 3 9 @ 3 ~ = = A eytind stead bas esith Doorn Atemejer te bel ; tuned ostth a too} how eom ot ators 3d <0.05 inch Ccordinate system, ASA) ReaD in a cating. Pyrce Fey. 1F the tool gery is changed, to off T= 6 AS"- O- 0.08 inch (coordinate aystero sna e & ano} atl other porame}ers remaky on changect» the cudtirg. forces eo fo Fo,» spectie cutting anergy Cin Thane) & Ue= Vo Co h vohere Uo bs the specie eoegeictent, and 4; i the uncut thickness es & & & en fn mm, The valve of parcentage change. tn colin Rocce Fen. bs Jato a ; Fa ound BEL Jo one decimol pla), Ree. (4 Fo XN dav Pie. CU emai. cay * $4 ice eags Bx G, DOWNLARD Tool OFFSET acy f OFFSET oot (S22) ekepe = X-8 Yore = (+6 H# NOSE RADIVS * 4 | +The tip of tool ts gue erfain vadlu: d curvature so ad to pre pogate Ane Shrtsa which appears af the tip 4 to improve the surface Finish. Pete ty Sob: thof & 4 ose wadius tnd b ob served a surface finish fmpous by 4 i beyond eextacy limit severe vi PeHHETEEE ETE TOOL WEAR AND FAILURE OF TOOL Gradual Sudden + Toot ceoe fot Boden as wall as aaa * the reason for sodden death of, tool can be ences sive Plastfe detormohton, suse encesstve impact toad, Baie | fatlore, Fatigue Jotlure , ete bot none ef the vealons eahich are werponsible for sudden death ef tecl cam be prectetecmin : . moreover He proportion ef seddun death of tox] H ven Jess hence we cho net com for ib. +The gradvol doth of deol totes plact due to graduod waa of Mt woke dace as well as at the Flame surface of tne Tes} which are on follows : OXIDATION, | DireustoN ¢ Duc to very high emp. at the fact of too} face atom stants Jo Atiuse torsands chip. the ‘rate. a dittusion sft! be higher if tne total motenas keeps bigh ahbintty towards ehfp motewral, | ADHESION. Due Jo eer high Femb. at the tool - chip tnferfacr soms cf JH clip moterial sdarts ro adhere to Me woke face tn form +, Sai smalk swall Spot type wetdments usbich are continuvosly aaa os ip and hened bweale usa me tho loss “{ materials from fae face. OXIDATION ! Bue do oH high temp. a ity Nayar ty maatorfal ot TK face. Keeps ont delve comb ny oly these enile tayerr are comhnosusly Awo.gged te he chip leading to les, oh materia’ prom role for, t tg eS Hard ond petite Cmpurthion prescnt ty come oe Bud oh a underside th ohtp leads ty loss: ef Maaterfal from Flank aud ents fact surface weapeodtvely , erveaking BREE As: jn. BUE Breaks , some th the Ruqmenh at carried by tne chip adoring which | he ent rune 4 A face 4 reading ear ot Farr, while ne}, rPYVDAPAPIAPPADA PPP P HHP PPP REAR ee CRATER Pere cox oll the oboue mechomUme ant Temponstble and the. colpath wu high temp. at the vale Face. pe SERED EUG E WERR, OT hich occurs af Clone sured oh deol cates! gy Flanta wear aud mainte rm ah BUE are ruspmslble Br Aon S NATURE OF PLASTIC DEFORMATION on CUTTING EDGE! +The woeam cohich occur? af wake face ts called ewaher BRAT, the cafe wean Gees starts ot some dfstony, Gem toot £Pp vohere Hu emp, is mayt mum, ‘abrasten’ amd WRU, GROWTH OF WEAR LOND W.R.7. TIME, ewit eo} fhe < FLANK WEAR Secondor ea seq ton region dg 6 Primary wut TIME ‘reg on) in the res uoaanr oe 3 the Shap at ea breake qutcty tue to excessive plate deformation & conse quenbiad emp. wise, T BFRY thot th seconda, we less ob oni rm oa. se region » Hye weit occurs eve Because ty this raion CAE), the mechanical wear ocours ¢ poets veoh temp. insensitive . “oe point F, Ma Flame wear Recownen re semarive twevense -foo) temp. wate th wtow become encessivel # EFFECT OF Vy rVg>V,>V4 Flank weot htmm) Th con be obsexved that 4 ise the cutting speed evittcal pint shifts towards tower time zone as sell 09 ‘ emHeal eotdth wf wear land ts abo Increasing. Pee Flank % = E wear > h I [77] « meosoemenk of Alonk vse is clatiely eater Bazed on Plarte wen vate Tay lor suggest the Gilets Test Ce equahten, ; j peeTHHCHL EGET IE SEG Ni oi apeed In min, T! Tool Wife tH minute. TAYLOR'S EXPONENTS 0.06 - OL 04-045 CAST Harp ALLOY. CARBIDES enero) 05-07 CEREMIC 062: s call me © | 0824452454 Quis, Two cotting. tools ave boeing. compared fxr machining. operation . The tool tie equaltons ae! Cavbtde tos: VT" = 2000 Hss toof | VTS = 200 where v ts the cutting speed in mtn and T & Whe in min, The carbide jool of provide higher tool if the cutting, speec| iy min oxceede @ 15 W 39-4 fo 49.3 Wco PHOS HHLEOC EET EUE Ng Te = 3008 —é ee sta 2200 Om ny BZ 2-0-8 _ 18-0. i ea 0.8 Tha SUF hv ef ceramic SX 1 componente can be at co opm ¢ G29 wat 39 © 42 prodocd coteneone cating tol Batcn | z N if ad + Te $2) = T4z —- tre Lo 10 122] 80 - S so [O25 | + NTM=C —= AOW eKzPec Nee foie | co} - | - So, Nz) = N,Z) = Nazd + NiZP = Nz ne n Sox Soo" = G0X122" oN Z" = Naz n= 0.33 soxgoo®* . 60x 73°99 vo Ze? 284-7 so, 10 tools ——= 284-7 components L too} ——= 28:17 2 29 componente, Ques. cohat ts the ayproximote perc entoge change th the UAyt o% a tool with zeyo wake angte used in orthogonal cutting. when ib clearance ew, ts chara fom 10 a SSH SDEHHHO ES: NOT Bee, decrease (&) 20h, inerrant © Fc deweare @) 40% % ed TeotiFe x 1 Flonk uxot vale oil Be: Enpot fe produce one work, piece t made up of i Money spent in mle operaht’on i TH overhead enct- % Money spent tn loading Ne Money apent tn Rapt advance . Ye Money spent tn saptd eehorn, Vi Money spent in voloodng. BR assume ano} od free cocts added together becomes Ox! ERNST MODEL ‘ & mle cart pew piece = +4 xt mle and De cost per piece, a! Toot cost of changing 4 Ce Nt No. of coorts piece produced blo succecs arias " e basic model eshich gives averoge writ eos} eon Foltovotng- coste J Ba 02. - i a — a iH 7 : 3 & 2 3 & ard freed speed freed oh aa oO 3 = ca z 5 § é z 2 q iS 5 > =| @ DEESIDE ESE ie oe [bert evaluated too! WR for Minimum total cost crffesta Maximum produchion wabe eriferta, . i. COST per piece = idtecoel/ Oa cotting CO aca, + Tool changing cour cy - + Toot ageing cost pteca.. let, Cm 2 direct tabouy vole +overhead cost th Relrmin Sy Regrinding. east per vegrind in Re tosh. Lt length WP tn mm Di diameter of wp in mm vi cuthing speed tn myn, $2 feed ty menfeew. Te? Teel changing Hme (TCT) Cin winote) Cm x (Falle Hime [ptece) HF [preee § cm x Cetting time pecs) Bir Toot Grindeng. oth litece 4 yx Avot plow pecs. aor vat Gee tooo gc a4 é i Cmx@ADt_ cap AOENER EN cott [ptece = Cmx fale Hime + Cm econ ees ED f. Fox Total minimum cost. een Differentiating £ equating 40

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