Instruction

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Metal Cutting

Ravi Upadhyai
Assistant Professor
GPERI
S. No. Orthogonal Cutting Oblique Cutting

1. The cutting angle of tool make The cutting angle of tool foes not make right
right angle to the direction of angle to the direction of motion.
motion.

The chip flow in the direction The chips make an angle with the normal to
2 normal to the cutting edge. the cutting edge.
In orthogonal cutting only two In oblique cutting three component of force
components of force are considered, cutting force, thrust force
3. considered cutting force and and radial force which cannot represent by
thrust force which can be 2D coordinate. It used 3D coordinate to
represent by 2D coordinate represent the forces acting during cutting,
system. so it is known as 3D cutting.

4. This tool has lesser cutting life This tool has higher cutting life.
compare to oblique cutting.
The shear force act per unit The shear force per unit area is low, which
area is high which increase the decreases heat develop per unit area hence
5. heat developed per unit area. increases tool life.
6. The chips flow over the tool. The chips flow along the sideways.
Free and restricted flow
v
v
The Mechanism of Chip Formation - YouTube.mp4
Single Point Cutting Tool Terminology – 3D
 Parameters
• Cutting Speed: Cutting speed is the distance travelled by the work
surface in unit time with reference to the cutting edge of the tool.
V = (ΠDN)/60 mm/min

• Feed: The feed is the distance advanced by the tool along the
workpiece in per revolution. (mm/rev)

• Depth of cut: It is the distance through which the cutting tool is

plunged into the workpiece surface. (mm)
 Cutting Tool

• Single point cutting tools : turning tools, shaping, planning

and slotting tools and boring tools
• Double or Two point cutting tools : drills
• Multipoint (more than two) cutting tool: Milling cutters,
Broaching tools, Hobs, Gear shaping cutters etc.
MULTIPOINT CUTTING TOOLS
 Tool Designation

1. ASA System

2. ORS System

3. NRS System

• ASA System – γy, γx, αy, αx, φe, φs, r (inch)

• ORS System – λ, γo, αo, αo’, φ1, φ, r (mm)

• NRS System – λ, γn, αn, αn’, φ1, φ, r (mm)

 ASA System

• Angles are measured with reference to 3 mutually perpendicular

planes.

• Understanding is easy.

• Measurements of angles is also easy.

• Analysis of machining is difficult.

 ORS System

• Angles measured with reference to major cutting edge.

• Analysis is easy.

• Understanding is difficult.

• For measurement of angles, we require special fixtures.

 Tool signature for single point cutting tool

• Shank
It is the main body of the tool.
• Flank
The surface of the tool adjacent to the
cutting edge.
• Face
The surface on which the chip slides.
• Nose
It is the point where the side cutting
edge and end cutting edge intersect.
• Nose Radius
Strengthens finishing point of tool.
• Cutting Edge
It is the edge on the face of the tool
which removes the material from the
work piece.
 Back Rack Angle
 As back rake angle increases,
• Forces on tool decreases.
• Strength of tool increases.
• Power required for machining is
decreases.
• Tool life increases.

• Maximum +ve rake angle used is 45

degree.

• -ve rake angle is used carbide cutting

tool.
 Side Rack Angle

As side rake angle increases,

• Strength of tool increases.
• Forces are decreases but in small
amount.
• Power is also decreases but in small
amount.
• Tool life is increases.

Generally side rake angle is in between 5 to

15 degree.
 Relief angle
 Provided to avoid rubbing between tool and workpiece.
 As relief angle increases,
• Strength decreases.
• Forces are slightly decreases.
• Tool life is slightly increases.
 Side cutting edge angle

• It increases tool life as, for the

same depth of cut; the cutting
force is distributed on a wider
surface
• It dissipates heat quickly for
having wider cutting edge. ™
• The side cutting edge angle of
the tool has practically no
effect on the value of cutting
force or power consumed for a
given depth of cut and feed. ™
• Large side cutting edge angles
are lightly to cause the tool to
chatter.
 End cutting edge angle

• The function of end cutting

edge angle is to prevent the
trailing front cutting edge of
the tool from rubbing
against the work.
• A large end cutting edge
angle unnecessarily weakens
the tool. It varies from 8 to
15 degrees.
 Nose Radius

 Mainly influence the surface

finish.
 With increase in nose radius,
surface finish increases.
 It increases the strength of
the cutting edge
Shear angle
 Tool material

• High carbon steel

• High speed steel
• Stellite
• Cemented carbide+
• Ceramics
• Cermets
• Diamond
• CBN (Cubic Boron Nitrite) or Borozone
 Properties of Cutting Tool Materials

• Harder than work piece.

• High toughness
• High thermal shock resistance
• Low adhesion to work piece material
• Low diffusivity to work piece material
 Types of chip formed

 Continuous chip
 Discontinuous chip
 Continuous chip with BUE
 Serrated chip
 Need and purpose of chip-breaking

• becomes dangerous to the operator and the other

people working in the vicinity
• may impair the finished surface by entangling with
the rotating job
• creates difficulties in chip disposal.
 Self breaking of chips
The curled chips may self break :
• By natural fracturing of the strain hardened outgoing chip after
sufficient cooling and spring back. This kind of chip breaking is
generally observed under the condition close to that which favours
formation of jointed or segmented chips
• By striking against the cutting surface of the job.
• By striking against the tool flank after each half to full turn
 Forced chip-breaking
• The hot continuous chip becomes hard and brittle at a
distance from its origin due to work hardening and cooling. If
the running chip does not become enough curled and work
hardened, it may not break
Chip breakers are basically of two types :
• In-built type • Clamped or attachment type
clamped type chip-breaker
Favourable effects:
• safety of the operator(s) from the hot, sharp continuous chip
flowing out at high speed,
• convenience of collection and disposal of chips,
• chances of damage of the finished surface by entangling or
rubbing with the chip is eliminated or more effective cutting
fluid action due to shorter and varying chip tool contact
length.
Unfavourable effects:
• chances of harmful vibration due to frequent chip breaking
and hitting at the heel or flank of the tool bit,
• more heat and stress concentration near the sharp cutting
edge and hence chances of its rapid failure., Surface finish may
deteriorate
 Concept of specific cutting pressure

• Specific cutting pressure is defined as the ratio

between the cutting force and the area of the chip
cross section.
• Area of shear plane
• Shear force on shear plane
• Normal force on shear plane
• Fs = Shear Force, which acts along the shear plane, is
the resistance to shear of the metal in forming the chip.
• Fn = Force acting normal to the shear plane, is the
backing up force on the chip provided by the workpiece.
• F = Frictional resistance of the tool acting against the
motion of the chip as it moves upward along the tool.
• N = Normal to the chip force, is provided by the tool
Cutting forces
• The largest magnitude is the vertical force Fc which
in turning is larger than feed force Ff , and Ff is larger
than radial force Fr . For orthogonal cutting system Fr
is made zero by placing the face of cutting tool at 90
degree to the line of action of the tool.
Cutting forces in orthogonal cutting
Forces acting on Chip in two-dimensional
cutting
Temperature Distribution in Turning
Thrust Force vs Rake Angle