Mechanics of Machining

METAL CUTTING

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 Basic Elements of Machining

▪ Workpiece
▪ Cutting tool
• Single point
• Multipoint
▪ Chip

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Basic Elements of Machining
Single Point Cutting Tool

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Basic Elements of Machining
Single Point Cutting Tool

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 Basic Elements of Machining
• Workpiece
• Cutting tool
– Single point
– Multipoint
• Chip

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Orthogonal Cutting & Oblique Cutting

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 Orthogonal Cutting
Cutting edge of the tool is perpendicular
to the direction of tool travel.
Direction of chip flow is perpendicular to
the cutting edge.
Chip coils in a tight flat spiral.
For same feed and depth of cut the force
which shears the metal acts on a smaller
area. So the life of the tool is less.
Produces sharp corners.
Smaller length of cutting edge is in
contact with the work.
Generally parting off in lathe, broaching
and slotting operations are done in this
method.
Oblique Cutting
Cutting edge is inclined at an angle less
than 90o to the direction of tool travel.
Chip flows on the tool face making an
angle.
Chip flows side ways in a long curl.
Cutting force acts on larger area and so
tool life is more.
Produces a chamfer at the end of the cut
For the same depth of cut greater length of
cutting edge is in contact with the work.
This method of cutting is used in almost all
machining operations. 7
Mechanics of Chip formation (Orthogonal)

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Mechanics of Chip formation (Orthogonal)

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Mechanics of Chip formation (Orthogonal)

AB = ls

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Forces Acting on a Single Point Cutting Tool

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Merchant’s Circular Force Diagram

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Merchant’s Circular Force Diagram

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Merchant’s Circular Force Diagram

s
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Merchant’s Circular Force Diagram

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Types of Chips

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Chip Breakers

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 Tool Life
Tool life can be defined as the time interval for which the tool works
satisfactorily between two successive sharpening/grinding.
There are three common ways of expressing tool life:
1. As time period (cutting time) in minutes between two successive
sharpening.
2. In terms of number of components machined between two successive
grinding
3. In terms of volume of material removed between two successive
grinding.
Factors affecting tool life

1. Cutting speed 4. Work material

2. Feed and doc 5. Nature of cutting
3. Tool geometry 6. Rigidity of machine and cutting tool
4. Tool material 7. Use of cutting fluid 18
 Tool Life
F W Taylor reported the relationship between tool life and
cutting speed as follows.

VT = C
n

V = Cutting speed (m/s)

T = Tool life (min)
n = Exponent depending on cutting condition and tool material
C = Constant equal to cutting speed (m/s) for a tool life of 1 min

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