MIN572: Advanced Manufacturing Processes

Date: 11-09-2023

Dr. Amit Choudhary

Assistant Professor
Dept. of Mech & Indus. Engg.
IIT Roorkee

Topic:
Cutting forces

Department of Mechanical & Industrial Engineering @ IIT Roorkee

 Need for Cutting Force Estimation
❑ Need for Cutting Force Estimation

▪ Estimation of cutting power consumption, which also enables selection of the power source(s) during design of
the machine tools

▪ Structural design of the machine – fixture – tool system

▪ Evaluation of role of the various machining parameters ( Speed, feed, depth of cut, material and geometry,
environment – cutting fluid) on cutting forces

▪ Study of behavior and machinability characterization of the work materials

▪ Condition monitoring of the cutting tools and machine tools.

Department of Mechanical & Industrial Engineering @ IIT Roorkee

 Cutting Force Components & their Significances
❑ Cutting Force
PX : Axial Force / Axial thrust force
PY : Transverse Force / Radial thrust force
PZ : Cutting Force/ Main Cutting Force
PXY : Thrust Force

❑ Significances
PY
▪ PZ : called the main or major component as it is the largest in magnitude. PX

▪ It is also called power component as it being acting along and being multiplied by VC PZ
decides cutting power consumption (PZ.VC).

▪ PY : may not be that large in magnitude but is responsible for causing dimensional
inaccuracy and vibration. R

▪ PX : It, even if larger than PY, is least harmful and hence least significant.

Department of Mechanical & Industrial Engineering @ IIT Roorkee

 Cutting Force Components & their Significances

P`XY P`Z

πC

PXY
PY PZ
PX

PZ
PX

PY PXY
R Feed

πR

Department of Mechanical & Industrial Engineering @ IIT Roorkee

 Merchant’s Circle Diagram (MCD)
❑ Cutting Force
PS: Shear Force
PN: Normal force to shear force
PN
F: Frictional force Vc
N: Force acting normal to rake surface
R
PZ: cutting force
PS
PXY: thrust force (𝑃ത 𝑋𝑌 = 𝑃ത X + 𝑃ത Y) β

❑ Use of MCD F
γ
▪ Experimentally determine PZ and PX
P
PXY = X
Sinφ
▪ Now determine R and Draw circle with diameter as R PZ R1
▪ Get F and N as intercepts in the circle by extending the surface and joining tips of
F and R Pxy
▪ Now determine PS. But βo is unknown.
𝑐𝑜𝑠𝛾 𝑎2
▪ 𝑇𝑎𝑛𝛽𝑜 = 𝜁−𝑠𝑖𝑛𝛾𝑜 ; 𝜁 =
𝑜 𝑎1

Department of Mechanical & Industrial Engineering @ IIT Roorkee

 Merchant’s Circle Diagram (MCD)
❑ Use of MCD
𝐹
▪ Apparent coefficient of friction 𝜇𝑎 = 𝑁
▪ Friction angle Tanη = 𝜇𝑎 𝑏1
𝑎1
𝑃
▪ Dynamic yield shear strength 𝜏𝑠 = 𝐴𝑠 β
𝑠

𝑡
𝑎1 𝑆𝑜 𝑠𝑖𝑛𝜑 × 𝑠𝑖𝑛𝜑 𝑡𝑆𝑜
𝐴𝑠 = × 𝑏1 = =
𝑆𝑖𝑛𝛽 𝑆𝑖𝑛𝛽 𝑠𝑖𝑛𝛽

▪ Cutting power consumption PC = PZVC + PXVFeed

PZVC
▪ Specific cutting energy US = 𝑀𝑅𝑅
φ
𝑡
𝑏1
❑ Limitations of MCD
▪ Valid only for orthogonal cutting
▪ Gives apparent coefficient of friction
▪ It is based on single shear plane theory

Department of Mechanical & Industrial Engineering @ IIT Roorkee

 Merchant’s Circle Diagram (MCD)
❑ Forces determined experimentally
▪ PX, PY, PZ Pxy

η PN
Vc
PZ
R

PS
F β

Department of Mechanical & Industrial Engineering @ IIT Roorkee

 Merchant’s Circle Diagram (MCD)
Pxy

❑ Estimation of Main cutting force PN

Vc
PZ = R cos(η-γo) ……. (1) PZ
cosγ
tanβo= ζ −𝑆𝑖𝑛γ𝑜 R
𝑜
PS = R cos(βo+η-γo) ……. (2) PS
β

From (1) & (2)

τs 𝑡𝑠 cos(η−γ𝑜 ) γ
PZ =
PS cos(η−γ𝑜 ) cos(βo+η−γ𝑜 )𝑆𝑖𝑛βo
PZ =
cos(βo+η−γ𝑜 )
τs = Dynamic yield shear strength
τ 𝑡𝑠
PS = τs × As = s
𝑆𝑖𝑛βo

𝑏1
𝑎1
β

Department of Mechanical & Industrial Engineering @ IIT Roorkee

 Merchant’s Circle Diagram (MCD)
❑ Estimation of Main cutting force Assignment: 4
τs 𝑡𝑠 cos(η−γ𝑜 ) 𝑑𝑃𝑧
PZ = =0
cos(βo+η−γ𝑜 )𝑆𝑖𝑛βo 𝑑𝛽

In case of machining, material removal is assumed to be 𝜋

2βo+η−γ𝑜 = 2 Merchant’s first solution
due to shear stress/shearing action. The material failure
takes place along the direction (β) in which the
resistance is minimum requiring the minimum cutting
energy. Thus considering the failure criteria as
minimum energy principal. PZ = 2τs 𝑡𝑠 cot βo

➢ Limitation:
▪ Dynamic yield shear strength is not
constant for ductile materials
▪ Shear plane angle is not fixed for brittle
materials

Department of Mechanical & Industrial Engineering @ IIT Roorkee

 Merchant’s Circle Diagram (MCD)

Assignment: 5 Assignment: 6

F = Pz Sinγo + Pxy Cosγo

❑ Lee & Shaffer Theory (Ductile)
N = Pz Cosγo - Pxy Sinγo
βo+η−γo = 45˚
PS = Pz Cosβ̥ - Pxy Sinβ̥
τs 𝑡𝑠 cos(η−γ𝑜 ) Pxy
PZ =
cos(βo+η−γ𝑜 )𝑆𝑖𝑛βo PN = Pz Sinβ̥ + Pxy Cosβ̥
η PN
Vc
PZ
PZ = τs 𝑡𝑠 (ζ/𝑐𝑜𝑠γ𝑜 −tanγ𝑜 +1)
R

PS
F β

Department of Mechanical & Industrial Engineering @ IIT Roorkee

Department of Mechanical & Industrial Engineering @ IIT Roorkee