MANUFACTURING II

CHEAP REMOVAL PROCESS – CUTTING FORCE

Tutor:
Ing. Luca Giorleo
 Useful Formulae:
t0 t0 ⋅ wc ⋅ Lc ⋅ ρ
Chip ratio: c= =
tc Q
PIISPANEN MODEL:

tan φ =
c cos γ π
2φP − γ =
1 − c sin γ 2
ERNST AND MERCHANT MODEL:

π γ ρ
φEM = + −
4 2 2
 Useful Formulae:
Forces decomposition inside Merchant
circle:

parallel (Fs) and normal (Fn) to the

shear plane: useful to study
stresses
along the shear plane;

parallel (Fz) and normal (Fx) to the

cutting speed: useful to evaluate
cutting power and tool stresses;

parallel (T) and normal (N) to the

rake: useful to discuss friction and
heat production on the secondary
zone.
Useful Formulae:

Along the shear plane:

Fs = R cos ( ρ − γ + φ )
Fn = R sin ( ρ − γ + φ )
Along cutting speed direction:
Fz = R cos ( ρ − γ )
Fx = R sin ( ρ − γ )
 Useful Formulae:

Along the rake face:

T = R sin ρ T
μ = = tgρ Coefficient
N = R cos ρ N of friction
Stresses:
Fs Fz cos φ sin φ − Fx sin φ
2
τ s = sin φ =
sl sl
Fn Fx cos φ sin φ − Fz sin φ
2
σ s = sin φ =
sl sl
 Useful Formulae:

MODIFIED MERCHANT MODEL:

τ S = τ S0 + k ⋅σ s
σ s = τ s ⋅ tg (φ + ρ − γ )
⎛1⎞
C = arctg ⎜ ⎟
⎝k⎠
τ s0
τs =
1 − k ⋅ tg (φ + ρ − γ )
 Useful Formulae:

SPECIFIC PRESSURE MODEL

Semi-empirical model based on the cutting pressure:

Fz
pt = [MPa] a=f=feed
S
p=d=depth of cut
h=chip thickness
b=chip width
Useful Formulae:

Specific pressure definition:

Fz
ps = [MPa]
1mm 2

Total cutting pressure:

 Exercise 1:

In an orthogonal cutting operation, the tool has a rake

angle = 15°. The chip thickness before the cut = 0.30 mm
and the cut yields a deformed chip thickness = 0.65 mm.
Calculate (a) the shear plane angle and (b) the shear
strain for the operation.
 Solution

a) Shear plane angle

t0 0.3
c= = = 0.46
tc 0.65
c(cos γ )
tan φ = = 0.5 ⇒ φ = 26.6°
(1 − c sin γ )

b) Shear strain

γ s = ctgφ + tg (φ − γ ) = 2.185
 Exercise 2:

A tube made of AISI 1040 (ρ=7.8 kg/dm3) steel is turned

orthogonally, using a rake angle=8°. The cutting speed
is 36 m/min, the feed is=0.3 mm/rev and the depth of cut
is 1.5 mm
The obtained chip is continuous and a 1 meter
long segment weighs 5.7 g

Find:
• Chip ratio
• Shear angle
 Solution

Volume evaluation (of the chip segment):

Q
5,7
V= = = 0,725 cm3
ρ 7,8

Under the hypothesis of constant chip width, we can

evaluate the height of the deformed chip

Remember that:
a = feed
S = ap = hb = t0 wc p = depth of cut
h = (undef.) chip thickness
b = chip width
 Solution

V 725
tc = = = 0,48 mm
wc ⋅ Lc 1,5 ⋅1000

Chip ratio:
t0 0,3
c= = = 0,62
tc 0,48

Shear angle evaluation:

c ⋅ cos γ
tgφ = = 0,672 φ = arctg (0,672) = 34D
1 − c ⋅ sin γ
 Exercise 3:

Consider an orthogonal cutting with:

d=3.5 mm, f=0.2 mm, γ =8°
After chip measurements we obtained a chip ratio c=0.37
Besides, some forces evaluation were done with the following
results:
Exercise 3:

Fz=1450 N : cutting force

Fx=900 N : normal force
Find the coefficient of friction, the shear
stress and the total force acting along the
shear plane

d=3.5 mm, f=0.2 mm, γ =8°

 Solution

Shear angle:
c ⋅ cos γ
tgφ = = 0,38 φ = arctg (0,4) = 21D
1 − c ⋅ sin γ

Coefficient of friction:
Fx + Fz ⋅ tgγ
μ= = 0,83
Fz − Fx ⋅ tgγ
Angle of friction:
ρ = arctg (μ ) = 40 D
 Solution

Section of the undeformed chip:

A = d ⋅ f = 0.7 mm 2

During an orthogonal cut the not deformed chip thickness is the

same of the feed
Solution

Shear stress:
Fz sin φ ⋅ cos(φ + ρ − γ )
τs = ⋅ = 530 MPa
A cos(ρ − γ )

Fs acting on the shear plane:

A
Fs = τ s ⋅ = 1030,5 N
sin φ
 Exercise 4:

We must perform a turning operation on a steel (AISI 1020) with

the following machining parameters:
d=3 mm, f=0.15 mm, γ=6°
We know that the shear stress is = 520 MPa and the shear angle
is 27.5°. Find Fz and Fx under the Merchant hypothesis
 Solution

Undeformed chip section:

A = p ⋅ a = 3,0 ⋅ 0,15 = 0,45 mm 2

The angle of friction can be obtained by the Merchant model

π ρ = 90 − 2 ⋅ φ + γ = 41
D D
2φEM − γ + ρ =
2
 cos ( ρ − γ )
Fz = A ⋅τ s ⋅ = 900 N
sin φ ⋅ cos (φ + ρ − γ )

Fx = Fz ⋅ tg (ρ − γ ) = 630 N
 Exercise 5:

Find stresses and the power required for a

turning operation with the following
parameters:
V=60 m/min R= 1450 N
d=3mm f=0.15.
Cutting angle Angle of friction

φ = 35 D
ρ = 25 D
Solution:

π π
2φEM − γ + ρ = γ = 2 ⋅ φ EM + ρ − = 5D
2 2

We can evaluate the force along the

cutting direction:

Fz = R cos ( ρ − γ ) Fz = 1362 N
Fx = R sin ( ρ − γ )
Knowing that force we can find the
power:
Pt = Fz ⋅ vt = 1362 W = 1,362 kW
To find the stress estate we must find before
the force parallel to the shear plane.

Fs = R cos ( ρ − γ + φ ) Fs = 830 N
Fn = R sin ( ρ − γ + φ ) Fn = 1188 N
Know the can find the medium stress estate on the shear
plane. It is necessary to speculate about the thickness and
the width of the chip

Fs Fz cos φ sin φ − Fx sin 2 φ

τ s = sin φ =
sl sl τ s = 60 MPa
Fn Fx cos φ sin φ − Fz sin 2 φ σ s = 85 MPa
σ s = sin φ =
sl sl
 26
Exercise 6

Referring to Ernst-Merchant model, you are

requested to evaluate the force developed during a
turning operation along the cutting speed direction.
Machining conditions are as follow:

τ s = 230 MPa
ρ = 25°
γ = 15°
thikness = s = 1mm
width = l = 8mm
 27
Solution
 28

We can evaluate shear angle as

follow:
π γ ρ
φEM = + − = 40 D
4 2 2

Once the shear stress is known we

can evaluate the corresponding force:

Fs τs
τs = ⋅ sin φ Fs = ⋅ sl = 2830 N
s ⋅l sin φ
 29

The resulting force is:

Fs
Fs = R ⋅ cos(ρ − γ + φ ) R=
cos(ρ − γ + φ )
= 4422 N

And the force along the cutting direction is:

Fz = R ⋅ cos(ρ − γ ) = 4355 N
 30
Exercise 7
Some tests on a carbon steel were performed in
orthogonal cutting conditions
d = 3 mm f [mm] Fz [N] Fx [N] c = t0 / tc
γ = 6° 0,1 1390 900 0,42
0,2 2300 1110 0,49
0,3 3110 1220 0,53
0,4 3830 1250 0,57

You are requested to evaluate the modified

Merchant model parameters.

For the evaluation follow these equation: kˆ = Δτ s Δσ s

 31
Solution

c ⋅ cos γ ⎛ c ⋅ cos γ ⎞
tan φ = φ = arctan⎜⎜ ⎟⎟
1 − c ⋅ sin γ ⎝ 1 − c ⋅ sin γ ⎠
Fx ⎛ Fx ⎞
= tan (ρ − γ ) ρ = γ + arctan⎜⎜ ⎟⎟
Fz ⎝ Fz ⎠
f [mm] φ ρ
0,1 24° 39°
0,2 27° 32°
0,3 29° 27°
0,4 31° 24°
 32

cos (φ + ρ − γ )
Fs = F z
cos (ρ − γ )
sin (φ + ρ − γ )
Fn = Fz
cos (ρ − γ )
f [mm] Fs [N] Fn [N]
0,1 910 1380
0,2 1540 2040
0,3 2120 2580
0,4 2630 3050
 33

sin ϕ sin ϕ
τ s = Fs σ s = Fn
a⋅ p a⋅ p

f [mm] τs [MPa] σs [MPa]

0,1 1220 1840
0,2 1170 1550
0,3 1150 1400
0,4 1130 1310
 34

kˆ = Δτ s Δσ s
τ s = τ s0 + k ⋅σ s
τˆ = τ − kˆ ⋅ σ
s0 s s

f [mm] Δτs Δσs stima k stima τs0

0,1 90 530 0,160 923
0,2 40 240 0,159 926
0,3 20 90 0,174 905
0,4 - -

k ≈ 0,165 τ s 0 ≈ 900 MPa

2ϕ + ρ − γ = C C = arctan(1 k ) ≈ arctan 6 = 80°