Machining

Prof. Dr. Melik DÖLEN

Middle East Technical University

Department of Mechanical Engineering

3/23/2020 ME 303 - Section 05a 1

 Content
 Terms and Definitions
 Chip Formation
 Cutting Forces and Force
Diagram
 Shear Angle
 Orthogonal Cutting
Geometry
 Mathematical Models
 Metal Removal Rate
 Power Requirement
 Examples
Photos from internet sites.

3/23/2020 ME 303 - Section 05a 2

 Terms and Definitions

Machining : Removal of
material in the form of
chips from the workpiece
by shearing with a sharp
tool.

Resultant Cutting Motion

in Cylindrical Turning

3/23/2020 ME 303 - Section 05a 3

 Terms and Definitions

Orthogonal Cutting Oblique Cutting

3/23/2020 ME 303 - Section 05a 4

 Terms and Definitions

Orthogonal Cutting Analogy in Turning (for k=00)

3/23/2020 ME 303 - Section 05a 5

 Terms and Definitions
Relative Motion
between tool and workpiece

Primary Secondary motion Depth of cut

motion adjustment
Cutting motion Feed motion

Cutting speed Feed rate Depth of cut

3/23/2020 ME 303 - Section 05a 6

 Chip Formation

3/23/2020 ME 303 - Section 05a 7

 Continuous Chip

 Common in machining ductile materials

3/23/2020 ME 303 - Section 05a 8

 Discontinuous Chip
 Machining brittle
materials
 Small rake angle
 Large depth of cut
 Machining ductile
materials at
 low cutting speed
 high feed

3/23/2020 ME 303 - Section 05a 9

 Continuous Chip with BUE
 Occurs in machining
ductile materials with
high friction at tool-
chip interface
 Chip welds to tool face
 Destroys accuracy and
surface finish
 Increases tool wear
 Can be reduced by
 decreasing depth of cut
 increasing cutting speed

3/23/2020 ME 303 - Section 05a 10

 Cutting Forces

n
ac a0 cutting
tool
Fc: tangential (main) cutting force
Ft: thrust (feed) cutting force
Ff: frictional force on rake
cutting
Fs

n tool Fn: normal force on rake
Fc 
 
n
Fs: shear force on shear plane

Fn Fr
Fn : normal force on shear plane
n
s
Ft s
Ff
Fr: resultant force
 : shear angle
Fn
n: normal rake angle
3/23/2020 ME 303 - Section 05a 11
 Cutting Forces
F 2 r  F c 2  F t 2  F s 2  F n2s  F n2  F f
2

Ft
tan(  -  n ) =
Fc
F s  F c cos  - F t sin 
F n s  F c sin   F t cos 
F f  F c sin  n + F t cos  n

F n  F c cos  n - F t sin  n

Ff
 = = tan 
Fn
3/23/2020 ME 303 - Section 05a 12
 Orthogonal Cutting Geometry
ac a0
ls  
sin  cos   n 
ac
sin   cos   n 
a0
ac
 rc
a0
rc cos  n
tan  
1  rc sin  n
3/23/2020 ME 303 - Section 05a 13
 Theoretical Models

 Only two of the simple thin shear-zone

models will be covered:
 Ernst and Merchant’s model
 Lee and Shaffer’s model

3/23/2020 ME 303 - Section 05a 14

 Ernst and Merchant Model
Common assumptions:
• Sharp tool tip  no rubbing
or ploughing between tool and
w.p.
• Two dimensional deformation
 no side spread
• Uniform stress distribution
on shear plane
• Resultant force on shear plane
equal and opposite to res.
force at chip-tool interface.

3/23/2020 ME 303 - Section 05a 15

 Main Assumption (EM Model)

Shear angle would take up such a value as to reduce

the work done in cutting to a minimum.

For given cutting conditions, work done in cutting is proportional

to Fc, it is necessary to develop an expression for Fc in terms of 
and then to obtain the value of  for which Fc is a minimum:

Fs  Fr cos      n 
 s Ac
Fs   s As 
sin 

3/23/2020 ME 303 - Section 05a 16

 Shear Angle (EM Model)
 s  shear strength of the work material on the shear plane
As  area of the shear plane
A c  cross - sectional area of the uncut chip
  mean angle of friction
 n  normal rake angle
 s Ac 1 Fc
Fr   0 to minimize Fc
sin  cos      n  
Fc  Fr cos    n  
 2     n 
 s Ac cos    n  2
 Fc 
sin  cos      n 
3/23/2020 ME 303 - Section 05a 17
 Lee and Shaffer’s Model
 Work material is rigid plastic.
Elastic strain is negligible.
 Behaviour of work material is

Stress
independent of the rate of
deformation.
 Temperature effects are
neglected.
 Inertia effects are neglected. Strain
 Uniform stress distribution at the
chip-tool interface.

3/23/2020 ME 303 - Section 05a 18

 Main Assumptions (LS Model)
 A slip-line field is formed in the triangular plastic
zone extending from the shear plane to the
interface between the tool and the chip where
no deformation takes place except for the
transmission of forces from tool-chip interface to
shear plane and for the material being stressed
to its yield point.
 All the deformation takes place in the plane
(Shear Plane) extending from the tool cutting
edge to the point of intersection of the free
surfaces of the work and the chip.

3/23/2020 ME 303 - Section 05a 19

 Assumptions (Cont’d)
 Maximum shear stress throughout the zone is s, shear
stress on the shear plane and two directions of this
max. shear stress are indicated by two orthogonal sets
of lines (slip lines).
 Top surface of the triangular plastic zone then becomes
a free surface across which no stresses are transmitted.
Therefore between this surface and the max. shear
stress plane (shear plane) there is an angle of /4.
 Principal stresses act on the chip-tool interface
(secondary def. Zone) at angles  and +/2.
 Directions of max. shear stress lie at  /4 to the dir. of
principal stress

3/23/2020 ME 303 - Section 05a 20

 Lee-Shaffer Theory (Cont’d)
n

max

e
ac
f
ter
rfac
e
2 1

In
S u
Free

ol
ss )

To
e
( S tr
2 = 90o 

i p-
Sl
ip

Ch
Li
ne
s
2 Fr
45o 1
1
Sh 
ea = 45o 2
rP
lan
Hence,  n /4
e 45o 
90o n


3/23/2020 ME 303 - Section 05a 21

 Metal Removal Rate
ac
ac

w = v.f.d d
k
where,
w: metal removal rate
f f
v: cutting speed
f: feed rate cutting conditions
d: depth of cut
Ac: f.d = undeformed chip cross sectional area

ac = f cosk
k :Side Cutting Edge Angle

3/23/2020 ME 303 - Section 05a 22

 Power Requirement

3/23/2020 ME 303 - Section 05a 23

 Power Requirement (Cont’d)

3/23/2020 ME 303 - Section 05a 24

 Power Requirement
Power required at the spindle:
P = Fc v = E w where Fc = cutting force
v = cutting speed
w = chip removal rate = v f d
E = spec. cut. energy

Fc v = E v f d E = (Fc/fd)
E is a function of material property and the undeformed chip thickness
If Eo is the specific cutting energy for an undeformed chip thickness of 1 mm,
then the specific cutting energy for a chip thickness ac :

E = E o . (ac ) => so ac E

E = Power / Material Removal Rate
E = (Fc.v) / (v.f.d) where ac = f . cos k

 E = (F c . cos k) / (ac . d)
3/23/2020 ME 303 - Section 05a 25
 Power Requirement
log E

log E1

logE2


log a log a
c1 c2

log a
c
- = ln (E1/E2) / ln (ac1/ac2)

E1/E2 = (ac1/ac2) -

 ranges between 0.2 - 0.4

3/23/2020 ME 303 - Section 05a 26
 Power Requirement

3/23/2020 ME 303 - Section 05a 27

 Power Requirement
EXAM PLE:

E = 3 .8 ( W - s e c /m m 3 ) v = 3 6 ( m /m in ) f = 0 .2 5 ( m m /r e v )
P o w e r a v a ila b le a t th e s p i n d le = 5 h p
F in d m a x im u m m e ta l r e m o v a l r a te a n d c o r r e s p o n d in g d e p th o f c u t.
(1 h p = 7 4 6 W )
 
 
P ow er 5 x 746  W 
w = =
E 3 .8  W 
 mm3 
 sec 
mm3 
w = 982 
sec 
P ow er
F =
V
N -m
5 x 746 
sec 
F =
36  m 
60  sec 
F = 6216 N 
m m3 
9 8 2
w sec 
d = =
V f 36  mm
103 0 .2 5 m m 
60  sec 
d = 6 .5 5 m m 

3/23/2020 ME 303 - Section 05a 28

 Specific Cutting Energy

3/23/2020 ME 303 - Section 05a 29

 Problem 1
In an orthogonal cutting test on mild steel, the following results
were obtained:
ac= 0.25 mm Fc = 900N
a0= 0.75 mm Ft = 450N
d = 2.5 mm n = 100
a) Calculate the mean angle of friction on the tool rake
b) Calculate the cutting ratio
c) Calculate the shear angle
d) Calculate the shear plane forces
e) Calculate the rake surface forces
f) Calculate the friction coefficient
3/23/2020 ME 303 - Section 05a 30
 Problem 2
For an orthogonal turning operation it was found that
power consumption of lathe when idle = 325 W
power consumption of lathe when cutting = 2580 W
For the following conditions:
spindle speed, N = 124 rpm; cutting speed, v = 24.5 m/min
depth of cut, d = 3.8 mm; feed rate, f = 0.2 mm/rev
Find:
a) specific cutting energy of the work material,
b) torque at the spindle,
c) cutting force,
d) specific cutting energy for 1 mm undeformed chip thickness
assuming = 0.4.
3/23/2020 ME 303 - Section 05a 31
 Problem 3

25 mm holes will be drilled on a steel workpiece, having a

hardness of Rc=45 {specific cutting energy, E = 77 W/(cm3/min)}
using an HSS twist drill at the following conditions:
cutting speed, v = 24.5 m/min
feed rate, f = 0.2mm/rev
Find:
a) the motor power if the efficiency of the transmission is 85%,
b) torque required.

3/23/2020 ME 303 - Section 05a 32

 Problem 4
A steel workpiece with a yield strength of 600 MPa is to be turned
using a coated WC insert for the following conditions:
• depth of cut, d = 2 mm
• feed rate, f = 0.4 mm/rev
• normal rake angle, n = 6o
• side-cutting edge angle, k = 12o
• end-cutting edge angle, ke = 8o
In the test, the magnitude of the resultant force is measured as 800 N
while the average thickness of the chip is registered as 0.8 mm. Find:
a) Kinematic friction coefficient () on the rake surface
b) Surface roughness attained

3/23/2020 ME 303 - Section 05a 33