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L6-Ta-202 Mechanics of Cutting PDF
L6-Ta-202 Mechanics of Cutting PDF
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)
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)
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
→ →
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
Ft + Fc tanα
µ= also, β = tan −1 ( µ )
Fc − Ft tan α
Dr. V.K.jain, IIT Kanpur 7
Foce Analysis
also,
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 )
Vs : Shear velocity
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
Thick Deformation Region:- Palmer, (At very low speeds) Oxley, kushina,
Hitoni
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
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
• 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