Force System during turning:

The force system in the general case of turning process is shown in fig.1. The resultant
cutting force R is expressible by its components: Px known as the feed force in the direction
of the tool travel; Py called as thrust force in the direction perpendicular to the produced
surface; and Pz the cutting force or the main force acting in the direction of the cutting
velocity vector.
After determining the individual components Px, Py and
Pz, resultant force R can be evaluated:

(1)

This three dimensional force system can be reduced to a

two-dimensional force system if in the orthogonal plane
, the forces are considered in such a way that the
entire force system is contained in the considered state
when

(2)

(3)

This is possible when the force Pxy is contained in plane which is possible only under
conditions of free orthogonal cutting. This corresponds to the orthogonal system of the first
kind for which the conditions are:
(i) 0 < Ø < 90°; (ii) λ=0; (iii) the chip flow direction lies on the plane .

Fig.2 shows the cutting forces for the case of orthogonal system of the first kind. An
orthogonal two dimensional system of second kind can be obtained by choosing λ and Ø in
such a manner that either Px or Py can be made zero.
For an orthogonal system of the second kind, Py is made zero by having λ = 0 and Ø = 90°
when the two dimensional force system is
 (4)

Fig. 3 shows the disposition of cutting forces in

plane orthogonal turning with λ = 0 and Ø =
90°.

Another, alternative way of having an

orthogonal system of the second kind is to have
Px = 0 during radial turning or facing operation
when

(4)

Fig. 4. Shows the disposition of cutting forces in plane orthogonal radial turning or facing
with λ = 0 and Ø = 0°.

For the purpose of analysis, a simplified scheme of chip formation is developed with the
following assumptions:

1. No contact at the flank i.e. the tool is perfectly sharp

2. No side flow of the chips(condition of plane strain)
3. Uniform cutting velocity
4. A continuous chip is formed with no BUE
5. Free cutting conditions (No chip flow deviation)
6. Chip is considered to be held in equilibrium by the action of the two equal and
opposite resultant forces and assume that these resultant forces are collinear.
 Fig.5 illustrates these forces R and and their
components. The following relationships

(5)

and (6)

suggest a circle representation of forces as done by

Merchant and indicated in fig. 6

Eir components

For a given tool shape with λ = 0 and , ∅ known; the tangential component of cutting force
Pz and the thrust force Pxy can be experimentally determined along with . From the values
of , , Pz and Pxy, the other component forces F, N, Pn and Ps can be easily estimated. For
orthogonal cutting of second kind;

Pxy = Px when ∅ 90° and λ = 0 (7)

and Pxy = Py when ∅ 0° and λ = 0 (8)

But for orthogonal cutting of the first kind i.e. when 0 < Ø < 90° with λ=0

Px = Pxy sin∅ (9)

Py = Pxy cos∅ (10)

Frictional force system at the chip tool interface

From the geometry of fig.7

!"# #$% (11)

and
− −

!"# − #$% (12)

!"# −#$%
Thus, ' ( ) *) *
#$% !"#
(13)

From eqn. 13, an equation for kinetic coefficient of friction can also be developed when

, 123 4 56 718 9 56
+ ./%0 (14)
- 18 4 56 :123 9 56

123 718 ;< 56

From which + (15)
18 :123 ;< 56

Where, + = kinetic coefficient of friction

and 0 = mean angle of friction at the friction surface

Force system at the shear plane

From the geometry of fig 8.

−= − >?

!"# − #$% (16)

=@ =? ?@ > ?@

#$% !"# (17)

Hence,
 !"# −#$%
) * ) *) *
#$% !"#
(18)

Further

tan ( 0− ) (19)

Stress in conventional shear plane

From the geometry of force relations of fig.8

cos(0 − ) (20)

and !"#( 0− ) (21)

substituting for R from eqn 21 to eqn 20

1I JKL(M:56 )
(22)
4 (N7M:56 )

But, O (23)

Where O = dynamic shear stress on the conventional shear plane of area mm2
<P QP
Now, 9
(24)

Now combining eqns 22, 23 and 24:

JKL(M:56 )
O # / 1 S1 ' ( (25)
#$%N.4 (N7M:56 )

Similarly,
LUV(M:56 )
O # / 1 S1 ' ( (26)
#$%N.4 (N7M:56 )

Evaluation of cutting power consumption and specific energy requirement

Cutting power consumption is a quite important issue and it should always be tried to be
reduced but without sacrificing MRR.
Cutting power consumption, P can be determined from,
C
P = P .V + P .V
C Z C X f
-W6
where, V = feed velocity = m/min [N=rpm]
f XYYY

Since both P and V , specially V are very small P .V can be neglected and then
X f f X f
P ≅ P .V
C Z C
Specific energy requirement, which means amount of energy required to remove unit volume
of material is an important machinability characteristics of the work material. Specific energy
requirement, U , which should be tried to be reduced as far as possible, depends not only on
s
the work material but also the process of the machining, such as turning, drilling, grinding
etc. and the machining condition, i.e., V , s , tool material and geometry and cutting fluid
C o
application.

Compared to turning, drilling requires higher specific energy for the same work-tool
materials and grinding requires very large amount of specific energy for adverse cutting edge
geometry (large negative rake). Specific energy, U is determined from
s
. \4
[
> .#

References :
1. NPTEL notes
2. Metal Cutting By A. Bhattacharjee