ORTHOGONAL AND OBLIQUE MACHINING ~ Metal cutting or commonly known as machining, is the most common phenomenon used in manufacturing industries. * Every product, big or small, undergoes a machining process to get final product % So the knowledge of basic types of metal cutting are most important. > If we talk about metal cutting two terms comes in our mind Q Orthogonal and Q Oblique. * These both are the metal cutting mechanism which is purely depending on the feed angle and cutting direction of tool.ORTHOGONAL MACHINING 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. In this cutting the cutting edge is wider than width of cut 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. Orthogonal cutting is cutting perpendicular to the work piece. For example if you have a 2x4 board on a circular saw table and you pull the blade crosscut across the boardORTHOGONAL AND OBLIQUE MACHINING SLIM Tle] oN fT Aare] Machined Tool Chip | Chip \ Motion of Workpiece Cutting edge at 90° -~ Cutting edge/ inclined Motion of Workpiece Orthogonal cutting Oblique cutting FIGURE 1. Two Types of machining processes (Orthogonal and Oblique Cutting)ORTHOGONAL MACHINING * Orthogonal machining (OM) is carried out mostly to better understand this complex process. + In OM, the tool geometry is simplified from the three-dimensional (oblique) geometry, as shown in Figure 2. “+ Using this simplified tool geometry. metals can be cut to test machining mechanics and theory. “* There are basically three orthogonal machining setups. as shown in Figure 3 1) Orthogonal Plate Machining a plate in a milling machine—low-speed cutting 2) Orthogonal Tube Turning end-cutting a tube wall in a turning setup— medium-speed ranges 3) Orthogonal Disk Machining end-cutting a plate feeding in a facing direction- high-speed cutting. research laboratories, in order “+ In oblique machining, as in shaping, drilling, and single-point turning, the cutting edge and the cutting motion are not perpendicular to each other. % In the orthogonal case. the cutting velocity vector and the cutting edge are perpendicularORTHOGONAL MACHINING INPUTS ‘OUTPUTS (Machine toot seletion Cutting tool parameters Measurements Lathe Tool design geometry Cuating forces + Miling machine + Too! angles Chip dimensions Nowe radius * Optical Edge radios “SEM *Materiat ‘Onset of Hardness shear directions Finish Pome * Coating ‘Surlace finish Tool wear, failures Detection Temperatures Vibrations Part sie Determinations ‘Specific horsepower. HP, Flow sires Chip ratios, ‘Shear front directions, & Velocities (chip, shear, and s0.6n) Friction coefficients, ‘rains. y ‘Stain rates, Cuting stitfoess, Ky Heat in toot FIGURE 2. The fundamental inputs and outputs to machining processes.ORTHOGONAL MACHINING Dynamometer to measure forces Miling machine table’ 2channet (2) OPM V Front view) See Figure FIGURE 3. Three ways to perform orthogonal machining, (a) Orthogonal plate machining on a horizontal milling machine, good for low-speed cutting, (b) Orthogonal tube turning on a lathe; high-speed. (c) Orthogonal disk machining on a lathe; very high-speed machining with tool feeding (ipr) in the facing direction. [J cumin tore sip cnan (6) 00M (Top viewsORTHOGONAL MACHINING Over oa Tool and OSD hammer holder Wert piee plate os9— f= 0D harnmer Dyranehitem—t oncom of Tener tent —= veining speed Table sees te ine = Seale Al seiahe teaver feod = 1 a 2© Hana for the roe food Pine Sj ee . FA taal xin na es ee ial movement ofthe table) vor fo section of| | h ‘he eating velosty | — TT —Wachine vod (al End view of OPM setup on horizontal mil. FIGURE 4. Schematics df 4's 4! esna speos. (8) Horizontal miting setup for PM using GSD. Front view. the orthogonal plate machining setups. (a) End view of table, quick-stop device (QSD), and plate being machined for OPM. (b) Front view of horizontal zit milling machine. (c) Orthogonal l2| plate machining with fixed tool, moving plate. The feed mechanism of the mill is used to is produce low cutting speeds. The feed of the tool is and the DOC fee gi no ain of nr oa is w, the width of the plate. So oOBLIQUE MACHINING “> Oblique cutting is another type of cutting in which the cutting edge of wedge shape cutting tool make a angle except right angle to the direction of tool motion. “+ This will affect the cutting conditions. + It is also known as 3D cutting because the cutting force develop during cutting cannot be represent by 2D coordinate or used 3D coordinate to represent. Oblique is cutting or drilling at any angle not perpendicular or parallel to the work piece. + For example if you saw into a board at a 45 degree angle. that is a oblique angleDIFFERENCE BETWEEN ORTHOGONAL AND OBLIQUE MACHINING + The basic and main difference between orthogonal cutting and oblique cutting is that in orthogonal cutting, cutting edge of the tool is perpendicular to the direction of motion but in oblique cutting the cutting edge make an angle with the direction of motion. * There are many other differences which are describe below. 8. No. [Orthogonal Cutting [Oblique Cutting 1. [The cutting angle of tool make right angle to[The cutting angle of tool does not make right angle to] the direction of motion the direction of motion. 2 [The chip flow in the direction normal to the/The chips make an angle with the normal to the cutting edge cutting edge. 3. [In orthogonal cutting only two components|In oblique cutting three component of force are lof force considered cutting force and thrust|considered, cutting force. thrust force and radial force force which can be represented by 2D] which cannot be represented by 21) coordinate. It uses [coordinate system 3D coordinate to represent the forces acting during| cutting. so it is known as 3D cutting. 4. [This tool has lesser cutting life compare to} This tool has higher cutting life oblique cutting 5. [The shear foree act per unit area is high|The shear force per u a is low, which decreases| which increase the heat developed per unit|heat develop per unit area hence increases tool life area. 6. [The chips flow over the tool The chips flow along the sideways “> Higher power is required in orthogonal cutting than the oblique cutting.DIFFERENCE BETWEEN ORTHOGONAL AND OBLIQUE MACHINING Another Source Orthogonal cutting Oblique Cutting The cutting edge of the tool is perpendicular to ‘the direction of feed motion. The cutting edge of the tool is inclined to the direction of feed motion. Chip flow is expected to ina direction perpendicular to the cutting edge The chip flow angle is more than zero. There are only two components of force: these components are mutually perpendicular. There are three mutually perpendicular forces acting while cutting process. The cutting edge is larger than cutting width. The cutting edge may or may not be larger than cutting width. Chips are in the form of a spiral coil. Chip flow is ina sideways direction. ‘High heat concentration at cutting region. Less concentration of heat at cutting region compared to orthogonal cutting. For a given feed and depth of cutting. the force acts on a small area as compared with oblique cutting. so tool life is less. Force is acting on a large area, results in more tool life Surface finish is poor Good surface finish obtained. Used in grooving. patting, slotting, pipe cutting Used almost all industrial cutting. used in drilling. grinding. milling