Lecture 7

CUTTING FORCES ON MACHINE TOOLS

Lecturer: Ir. Agus Hariyanto, M.T.

Stresses on Machine Tools

Stresses produced during machining, which tend to deform the machine
tool or a work piece [WP], are usually caused by one of the following
factors:
1. Static loads that include the weight of the machine and its various parts
2. Dynamic loads that are induced by the rotating or reciprocating parts
3. Cutting forces generated by the material removal process
Driving Units in Machine Tools
There are two main types of motions that are effective;
1-Rotational motion
2-Lineer (forward-backward motions)
The Extreme Spindle Speeds Of Amachine Tool Main Gearbox Nmax
And Nmin Can Be Determined By
 Driving mechanisms that arrange revolutions
can be classified into two categories:
A-Steppless speed drives
B-Stepped speed drives
STEPPING OF SPEEDS
Let n1, n2, …, nz be arranged according to arithmetic progression. Then
n1 –n2 = n3 –nz = constant. Accordingly, for an economi calcutting speed
vo, the lowest speed v1 is not constant; it decreases with increasing
diameter. Therefore,the arithmetic progression does not permit
economical machining at large diameter ranges.

If the revolutions are stepped, then we use some diagrams and

progressions. This diagram is called sawtooth diagram
 Geometric progression
The percentage drop from one step to the other is constant, and the absoluteloss of
economically expedient cutting speed Δv is constant all over the whole diameter range.
The relative loss of cutting speed Δvmax/vois also constant. Geometric progression,
there fore, allows machining to take place between limits vo and vu independent of the
work piece[WP] diameter, where vo is the economical cutting speed and vu is the
allowable minimum cutting speed.
Usage of both progression together
 Example: Orthogonal Cutting

ACTUAL CHIP FORMATION

Discontinuous chip. When relatively brittle materials (e.g., cast irons) are machined at
low cutting speeds, the chips often form into separate segments (sometimes the
segments are loosely attached). This tends to impart an irregular texture to the
machined surface. High tool–chip friction and large feed and depth of cut promote the
formation of this chip type.
Continuous chip. When ductile work materials are cut at high speeds and relatively
small feeds and depths, long continuous chips are formed. A good surface finish
typically results when this chip type is formed. A sharp cutting edge on the tool and
low tool–chip friction encourage the formation of continuous chips. Long, continuous
chips (as in turning) can cause problems with regard to chip disposal and/or tangling
about the tool. To solve these problems, turning tools are often equipped with chip
breakers (Section 23.3.1).
Continuous chip with built-up edge. When machining ductile materials at low-to medium
cutting speeds, friction between tool and chip tends to cause portions of the
work material to adhere to the rake face of the tool near the cutting edge. This
formation is called a built-up edge (BUE). The formation of a BUE is cyclical; it
forms and grows, then becomes unstable and breaks off. Much of the detached BUE
is carried away with the chip, sometimes taking portions of the tool rake face with it,
which reduces the life of the cutting tool. Portions of the detached BUE that are not
carried off with the chip become imbedded in the newly created work surface,
causing the surface to become rough.
Serrated chips (the term shear-localized is also used for this fourth chip type). These
chips are semi-continuous in the sense that they possess a saw-tooth appearance that
is produced by a cyclical chip formation of alternating high shear strain followed by
low shear strain. This fourth type of chip is most closely associated with certain
difficult-to-machine metals such as titanium alloys, nickel-base superalloys, and
austenitic stainless steels when they are machined at higher cutting speeds. However,
the phenomenon is also found with more common work metals (e.g., steels) when
they are cut at high speeds
More realistic view of
chip formation,
showing shear zone
rather than shear
plane. Also shown is the
secondary shear zone
resulting from tool–chip
friction.
 FORCES IN
METAL CUTTING
Example: Shear strength
THE MERCHANT EQUATION
 Example Estimating Friction Angle

Approximation of Turning by Orthogonal Cutting

The orthogonalmodel can be used to approximate turning and certain
other single-point machining operations so long as the feed in these
operations is small relative to depth of cut. Thus, most of the cutting will
take place in the direction of the feed, and cutting on the point of the
tool will be negligible. Figure 21.13 indicates the conversion from one
cutting situation to the other.
POWER AND ENERGY RELATIONSHIPS IN MACHINING
Example Power Relationships in Machining
 CUTTING TEMPERATURE

ANALYTICAL METHODS TO COMPUTE CUTTING TEMPERATURES

Example : Cutting Temperature
Forces in machining
 Jenis 2 Material Pahat
Berikut merupakan urutan material pahat dari yang paling lunak tetapi
ulet sampai paling keras tetapi getas (Rochim, 1993):
a. Baja Karbon Tinggi (High Carbon Steel; Carbon Tool Steels)
b. HSS (High Speed Steels; Tool Steels)
c. Paduan Cor Nonferro (Cast Nonferous Alloys; Cast Carbides)
d. Karbida (Cemented Carbides; Hardmetals)
e. Keramik (Ceramics)
f. CBN (Cubic Boron Nitrides)
g. Intan (Sintered Diamonds dan Natural Diamond )
Pengaruh Keausan Pahat
Selama proses pembentukan geram berlangsung, pahat dapat mengalami kegagalan
dari fungsinya karena berbagai sebab antara lain: (Rochim, 1993)
a. Keausan yang secara bertahap membesar (tumbuh) pada bidang aktif
pahat.
b. Retak yang menjalar sehingga menimbulkan patahan pada mata
potong pahat.
c. Deformasi plastik yang akan mengubah bentuk/geometri pahat.
 Pengaruh Umur Pahat
Umur pahat dapat didefinisikan sebagai lamanya waktu yang diperlukan
untuk mencapai batas keausan yang ditetapkan. Keausan pahat akan
menimbulkan efek samping diantaranya yaitu : (Rochim, 1993)
a. Adanya kenaikan gaya potong,
b. Terjadinya getaran/chatter,
c. Penurunan kehalusan permukaan hasil permesinan
d. Perubahan dimensi/geometri produk.

Fungsi Cairan Pendingin, Yaitu :

a. Menurunkan gaya potong
b. Melumasi elemen pembimbing
c. Memperhalus kualitas permukaan hasil permesinan
d. Membersihkan geram dan bidang geram pada saat pemotongan
e. Proteksi korosi pada permukaan benda kerja yang baru terbentuk
Jenis cairan pendingin yang sekarang ini banyak digunakan :
a. Minyak bumi [100% bahan minyak bumi ]
b. Minyak yang 60-90% minyak bumi dapat larut (soluble oils) dengan
zat aditif lainnya.
c. Sintetik [Merupakan cairan kimia yang dicampur dengan air ]
d. Semi sintetik [Air dengan mengandung 2-30% minyak bumi]

Perencanaan Dan Perhitungan Proses Bubut

Elemen dasar proses bubut dapat dihitung dengan menggunakan
rumus-rumus dan Gambar berikut :
 Parameter Pemotongan Yang Penting Untuk
Proses Frais meliputi:
Kecepatan Potong, Putaran Spindel, Kedalaman Pemakanan, Gerak
Makan Per Gigi, Kecepatan Penghasilan Geram Dan Waktu Pemesinan.