THEORY OF METAL CUTTING

Unit – I
Course : Metal Cutting and Machine Tools
Learning Outcomes

Student will be able to

 Know the basic elements of metal cutting process
 Identify appropriate tool angles for cutting different work
materials.
 Prevent the formation of BUE using appropriate machining

conditions.
 Analyze the cutting forces and power required during orthogonal

cutting process.
 Adjust cutting parameters to produce components at low cost
and minimum time with good quality.
 Calculate life of cutting tool.
 Select appropriate cutting tool material suitable for given
conditions.
 Know the use of cutting fluids .
Basic Elements of Machining

 Work piece
 Tool
 Chip
 Cutting Fluid
 Classification of Cutting Tools

 Single point tools : Those having only one cutting

edge.
❖ Ex: Lathe tools, shaper tools, planer tools,

boring tools, etc.

 Multi-point tools: Those having more than one
cutting edge.
❖ Ex: milling cutters, drills, broaches, grinding

wheels, etc.
Classification of Cutting Tools
Classification of Cutting Tools

The cutting tools can be classified according to the

motion as:
 Linear motion tools:

❖ Ex: Lathe, boring, broaching, planing, shaping

tools, etc.
 Rotary Motion tools:

❖ Ex: milling cutters, grinding wheels, etc.

 Linear and Rotary Motion tools:

❖ Ex: drills, honing tools, boring heads, etc.

Geometry of Single Point Cutting Tool

Turning Operation
Geometry of Single Point Cutting Tool
Geometry of Single Point Cutting Tool
Geometry of Single Point Cutting Tool
 Tool Signature or Tool Designation

Tool Geometry in Coordinate System or ASA system:

❖ αy = Top Rake / Back Rake angle

❖ αx = Side Rake angle

❖ βy = End Relief / Clearance angle

❖ βx = Side Relief / Clearance angle

❖ Φe = End Cutting Edge Angle

❖ Φs = Side Cutting Edge Angle

❖ R = Nose Radius

For Example:
8,10,6,6,6,10,2
 Tool Signature or Tool Designation

Tool Geometry in Orthogonal System:

❖ λ = Angle of Inclination

❖ α = Orthogonal Rake Angle

❖ γ = Side Relief Angle

❖ γ1 = End Relief Angle

❖ Φ1 = Auxiliary cutting edge angle

❖ Φ0 = Approach angle

❖ R: Nose Radius

For Example:
8,10,6,6,6,10,2
 Inter-Relationship Between ASA and
ORS System

 The following relationships will helps to convert

some tool parameters from ASA to ORS.

tan   tan  y cos 0  tan  x sin 0 (1)

tan   tan  y sin 0  tan  x cos 0 (2)

tan  x  sin 0 tan   cos 0 tan  (3)

tan  y  cos 0 tan   sin 0 tan  (4)
Types of Cutting
Orthogonal Cutting Oblique Cutting
Difference between Orthogonal and
Oblique Cutting

Orthogonal Cutting Oblique Cutting

The cutting edge of the tool is perpendicular The cutting edge is inclined at an angle with
to the direction of tool travel the normal to the direction of tool travel.

The cutting edge clears the width of the The cutting edge may or may not clear the
workpiece on either ends. width of the workpiece.
The chip flow over the tool. The chip coils The chip flows on the tool face making an
in tight. angle with the normal cutting edge. The
chip flows sideways in a long curl.
Only two components of the cutting force Three components of the forces acting on
acting on the tool. the tool
The force which act or shears the metal It acts on larger area and thus tool life is
acts on a smaller area and therefore, the more.
heat developed per unit area due to friction
along the tool work interface is less and the
tool life is less.
Difference between Orthogonal and
Oblique Cutting
Chip Formation
Types of Chips

 Discontinuous or Segmental Chips

 Continuous Chips

 Continuous Chip with built-up edge (BUE)

Discontinuous or Segmental Chips

Factors responsible:
 Brittle materials

 Small Rake Angle

 Too much of depth of cut

 Ductile with low cutting speed

Continuous Chips

Factors responsible:
 Ductile materials

 High Cutting Speed

 Bigger Rake Angle

 Fine Feed

 Keen Cutting Edge

Continuous with BUE

Factors responsible:
 Ductile materials

 Low Cutting Speed

 Small Rake Angle

 Excessive Feed

 Lack of Lubricant
Continuous with BUE

 Adverse effects of built-up edge formation:

 Rough surface finish.
 Fluctuating cutting force causing vibrations in
cutting tool.
 Chances of carrying away some material from the
tool by the built-up surface, producing crater on
the tool face and causing tool wear.
 Precautions to avoid built-up edge formation:
 The coefficient of friction at the chip-tool interface
should be minimized by means of polishing the
tool face.
 Adequate supply of coolant.
Chip Control and Chip Breakers

 Adverse effect of coiled chips on machining:

 Effects the tool life by spoiling the cutting edge,
creating crater and rising the temperature.
 Lead to poor surface finish on the work piece.
 If the chip gets curled around the rotating w/p
or tool, it may be hazardous the machine
operator.
 If a large and continuous coil is allowed to be
formed, it may engage the entire machine and
even the work piece, its quite dangerous.
 Very large coils offer a lot of difficulty in their
removal.
Chip Breakers

Common methods used for chip breaking

are :
 By control of tool geometry:

 By obstruction method :
Chip Breakers

Step Type

Groove Type

Secondary Rake Clamp Type

Chip thickness ratio
Chip thickness ratio
 Chip thickness ratio

 t0 = chip thickness prior to deformation

 tc = chip thickness after deformation
 Thickness of the upward flowing chip is
more than the actual depth of cut.
t0 > tc
 Because, chip velocity < velocity of cut.
t0
Chip thickness ratio, r 
tc
1 tc
Chip reduction coefficient, k  
r t0
 Chip thickness ratio

b1t0 L1  b2tc L2

 t0 L1  b2tc  b1  b2 
t0
From triangle OAP, OP 
sin 
tc
From triangle OBP, OP 
cos(   )
r cos 
tan  
1  r sin 
t0 sin 
and r  
tc cos    
➢ In orthogonal cutting,
Volume of the chip produced = Volume of the metal cut.
 Velocity Relationships

vc v vs
Analytically,  f 
sin(90  (  )) sin  sin(90  )
v c sin  Volume of material per unit time  Volume of material flowing up the chip
vf 
cos(  )  vc  t 0  w  vf  t c  w
v f  v c  r  r  sin   v f  v c  r As, r 
t0
 cos(-)  tc