Cutting processes

2.008 Design & Manufacturing

Objectives
II „
„ Product quality: surface, tolerance
„ Productivity: MRR , Tool wear
Spring 2004 „ Physics of cutting
„ Mechanics
Metal Cutting II „ Force, power
„ Tool materials
„ Design for manufacturing
2.008-spring-2004
S.Kim 1 2
2.008-spring-2004 S.Kim

Orthogonal cutting in a lathe Velocity diagram in cutting zone

V Vs Vc
= =
cos( φ −α ) cos( α ) sin( φ )
Assume a hollow shaft
Vc to sin ( φ )
= = r =
V tc cos( φ −α )
Shear plane
Vsin( φ )
Vc =
cos( φ −α )
Shear angle
To: depth of cut
Vc t o sin( φ )
= =r =
V tc cos( φ −α )

Rake angle
Cutting ratio: r <1

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E. Merchant’s cutting diagram

FBD of Forces

Fs
β = Friction Angle F= R ⋅sin( β ) ( )
Ft = R ⋅ sin β-α
Fc φ
µ = tan ( β )
N = R ⋅cos( β ) ( )
Fc = R ⋅ cos β-α
Ft
Ft β−α
Fn
Fc
R Fs = Fc ⋅ cos φ ( ) − Ft ⋅ sin( φ ) = Rcos(φ + β − α)
β
Fn = Fc ⋅ sin φ ( ) + Ft ⋅ cos( φ )
F
α
F Ft + Fc ⋅tan ( α )
µ = =
α N Fc − Ft ⋅tan ( α )
Source: Kalpajkian N
Typcially: 0.5<µ < 2

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 o α β
φ = 45 + −
Analysis of shear strain Shear Angle 2 2

w
Fs

Fc
φ

γ =
bc + cd
ac
(
= cotφ + tan φ − α ) Maximize shear τ = As = A
Fs Fs

„ What does this mean: stress sinφ

dτ
„ Low shear angle = large shear strain dϕ = 0
„ Merchant’s assumption: Shear angle adjusts Fs = As ⋅σs
to minimize cutting force or max. shear stress Minimize Fc
Fs = Fc ⋅ cos φ ( ) − Ft ⋅ sin( φ ) = Rcos(φ + β − α)
„ Can derive: o α β
φ = 45 + − Fc = R ⋅ cos β-α ( ) dFc
= 0
2 2 dϕ
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Power Cutting zone pictures

continuous secondary shear BUE
Power input : Fc ⋅ V => shearing + friction
MRR (Material Removal Rate) = w.to.V

Power for shearing : Fs ⋅ Vs

F ⋅V
Specific energy for shearing : us = s s
w ⋅ to ⋅ V
Power dissipated via friction : F ⋅ Vc MRR

F ⋅Vc
Specific energy for friction : u f =
w ⋅ to ⋅ V
F ⋅ Vc F ⋅V
Total specific energy : u s + u f = + s s
w ⋅ to ⋅ V w ⋅ t o ⋅ V
serrated discontinuous
Experimantal data
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Chip breaker Cutting zone distribution

Continuous chip: bad for automation
Hardness Temperature
316

- Stop and go 500

- milling
770

Mean temperature: CVafb

HSS: a=0.5, b=0.375
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 Built up edge Tools
-High T
„ What is it? HSS (1-2 hours)
-High σ
„ Why can it be a good thing? -Friction
-Sliding on cut surface
„ Why is it a bad thing?
„ Thin BUE
„ How to avoid it…

•Increasing cutting speed

•Decreasing feed rate
•Increasing rake angle
•Reducing friction (by applying cutting fluid) Inserts

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Taylor’s tool wear relationship

Tool wear up close (flank wear)
Depth of cut line
Flank wear F. W. Taylor, 1907
T = time to failure (min)
V ⋅ Tn = C V = cutting velocity ( fpm )

V ⋅ Tn ⋅ d x ⋅ f y = C
Workpiece d = depth of cut
Wear land Crater wear hardness
f = feed rate
Ex. T = C7 ⋅ V-7 ⋅ d −1 ⋅ f −4

Optimum for max MRR?

fpm
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2.008-spring-2004 S.Kim Source: Kalpajkian 2.008-spring-2004 S.Kim Source: Kalpajkian

Taylor’s tool life curves

(Experimental) What are good tool materials?
Coefficient n varies from:
Hardness
„
„
Steels Ceramics
0.1 0.7 „ wear
„ As n increases, cutting speed can be „ temperature
increased with less wear. „ Toughness
„ fracture
„ Given that, n=0.5, C=400, if the V
reduced 50%, calculate the increase of Log scale
tool life?

Kalpakjian 17 18
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 History of tool materials HSS
„ High-speed steel, early 1900
„ Good wear resistance, fracture resistance, not so expensive
„ Suitable for low K machines with vibration and chatter, why?
„ M-series (Molybdenum)
„ Mb (about 10%), Cr, Vd, W, Co

„ Less expensive than T-series

„ Higher abrasion resistance

„ T-series (Tungsten 12-18%)

„ Most common tool material but not good hot hardness

Trade off: Hardness vs Toughness

wear vs chipping
Sandvik Coromant, Kalpakjian 19 20
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Carbides Crater wear

„ Hot hardness, high modulus, thermal stability „ Diffusion is dominant for crater wear
„ Inserts
„ A strong function of temperature
„ Tungsten Carbide (WC)
„ (WC + Co) particles (1-5 µ) sintered „ Chemical affinity between tool and workpiece
„ WC for strength, hardness, wear resistance „ Coating?
„ Co for toughness

„ Titanium Carbide (TiC)

„ Higher wear resistance, less toughness
„ For hard materials
„ Uncoated or coated for high-speed machining
„ TiN, TiC, TiCN, Al2O3
„ Diamond like coating
„ CrC, ZrN, HfN
Crater wear
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Multi-phase coating Ceramics and CBN

Custom designed coating for heavy duty, high speed, interrupted, etc.
„ Aluminum oxide, hardness, high abrasion resistance, hot
hardness, low BUE
TiN low friction
„ Lacking toughness (add ZrO2, TiC), thermal shock
Al2O3 thermal stability „ Cold pressed and hot sintered
„ Cermets (ceramic + metal)
TiCN wear resistance
„ Al2O3 70%, TiC 30%, brittleness, $$$

„ Cubic Boron Nitride (CBN)

„ 2
nd hardest material

„ brittle
Carbide substrate
hardness and „ Polycrystalline Diamond
rigidity

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 Range of applications Chatter
ƒ Severe vibration between tool and the
workpiece, noisy.
High
ƒ In general, self-excited vibration
(regenerative)
ƒ Acoustic detection or force
V measurements
ƒ Cutting parameter control, active
control

f High
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Turning parameters Sol.

„ MRR = π Davg. N. d . f „ Davg=(0.5+0.48)/2= 0.49 in
„ N: rotational speed (rpm), f: feed (in/rev), d: depth of cut (in) „ V=π. 0.49.400 = 615 in/min
„ l; length of cut (in)
„ d=(0.5-0.48)/2=0.01 in
„ Cutting time, t = l / f N
„ F=8/400=0.02 in/rev
„ Torque = Fc (Davg/2)
„ Power = Torque. Ω „ MRR=V.f.d=0.123 in3/min
„ 1 hp=396000 in.lbf/min = 550 ft.lbf/sec „ Time to cut=6/8=0.75 min

Example P=1.47 x 0.123 = 0.181 hp=Torque x ω

„ 6 inch long and 0.5 in diameter stainless steel is turned to 0.48 1hp=396000 in-lb/min
in diameter. N=400 rpm, tool in traveling 8 in/min, specific T=P/ω=Fc. (Davg/2)
energy=4 w.s/mm2=1.47 hp.min/in3
Then, Fc=118 lbs
„ Find cutting speed, MRR, cutting time, power, cutting force.

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Drilling parameters Sol

⎛ π D2 ⎞
„ MRR: MRR = ⎜ ⎟f ⋅ N „ MRR=π (10x10/4 ) . 0.2 . 800 =210 mm3/s
⎝ 4 ⎠
„ Power: specific energy x MRR „ Power= 0.5 W.s/mm2 . 210 mm3/s
=105 W = 105 N.m/s
„ Torque: Power/ω
= T.ω
=T 2π. 800/60
„ A hole in a block of magnesium alloy, 10 mm drill bit, =1.25 N.m
feed 0.2 mm/rev, N=800 rpm
„ Specific power 0.5 W.s/mm2
„ MRR
„ Torque

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 Milling Milling parameters (slab)
„ Parameters:
„ Cutting speed, V=πDN
„ tc, chip depth of cut
d; depth of cut approximation
„
2 fd
„ f; feed per tooth tc =
D
„ v; linear speed of the v
workpiece f =
Nn
„ n; number of teeth
l + lc
„ t; cutting time, t =
v
„ w; width of cut
lwd
MRR = = wdv
„ Torque: Power/ω t
Chip continuous? „ Power: sp. Energy x MRR

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DFM for machining

„ Geometric compatibility

„ Dimensional compatibility
„ Availability of tools
„ Drill dimensions, aspect ratio
„ Constraints
„ Process physics
„ Deep pocket
„ Machining on inclined faces
„ Set up and fixturing
„ Tolerancing is $$$
„ Minimize setups

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