Force Dynamometer, Force

and velocity relationship

Name: Makwana Saurav. L

En.No: 160010119039
Forces and Mechanics of Cutting

• Why should we know?

– Power requirement for the machine tool can be
calculated
– Design of stiffness, etc. for the machine
tolerances
– Whether workpiece can withstand the cutting
force
• Ernst and Merchant (1941) did the first
scientific analysis
– Normal = N F

– Along the tool = F N
• FC and FT along and normal to cutting along
the direction of tool movement with
velocity, ‘v’.

– FF 
cos
Fsin
(1) 
 
C S N

– F
TFN 
cos
F
Ssin
(2)
F  F C sin   F T cos  (3)

N  F C cos   F T sin  (4)

F S  F C cos   F T sin  (5)

F N  F C sin   F T cos  (6)

FS
R  (7)
cos       
F C  R cos      (8)

F T  R sin      (9)
• We can measure FC and FT using force
dynamometer.
• FS, FN, F, and N can be found.
– FS and FN from equations 5 & 6.
– F and N from 3 & 4

F
 tan
 (   friction angle)
• N

FsinF 
Tcos
C Eq. 10
F
C 
cosF 
Tsin
• Cutting Force FC depends on
– FC increases as t0 increases
– FC decreases as rake angle increases and as
speed increases
• Why FC is affected by speed:
– As speed goes up, shear angle goes up, and
friction reduces.
• Forces can also be affected by the nose
radius. Large nose radius increases force.
(Blunt tool)
• Large nose radius can create positive rake
angle and cause rubbing and create plastic
deformation.
• Coefficient of friction in metal cutting range
from 0.5 to 2.0
• Shows how high friction can rise on the
chip-tool interface
• Forces on the tool tip are very high because
of small contact area.
 Stresses
• Average shear stress   FS
AS
• Average normal stress FN

AS
• The area where the stress acts (area of shear plane)
wt0
AS 
sin
• AS can be increased by increasing t0.
•  is independent of rake angle
•  decreases with increase in rake angle.
• Consequently, normal stress in the shear
plane has no effect on the magnitude of
shear stress.
• Problems in finding stresses on the rake
face:
– Hard to find the contact on the rake face.
– Stresses in practice is not uniformly distributed
on the rake face.
 Shear-angle relationship
• Let’s take friction angle as  In the previous slides we
FC Rcos   called this l
FS Rcos  
wt
AS  0

sin

FS FCsec
 
 cos
  sin
( )

AS t0
• Assume is independent of  .

Differentiate with respect to  and equate to 0
(zero).
 
tan
 
cot  90
tan 




45
o
(A)
22
• The equation (A) shows that
If  decreases and/or  increases then  decreases.
• In practice this analysis is corrupted because of
several reasons like:
– Shear stress is effected by normal stresses.
–  is effected by  etc.
– (see graph 8.19)
 Specific Energy
• Total power = FCV
• If width of unit = ‘W’
• Total energy/unit volume of material
removal.
F V F
ut  C
 C
t0V t0
• Frictional specific energy:
u
FV
  CFr r F
Csin F
t 

cos
f

t
V
0 
t 0 
t 0
• Power required to shear along the plane
FS V S
us 
 t 0V
ut  u f  u s

• As uf increases, shear angle decreases, and

hence us goes up directly.
• Thus friction plays an important part in
metal cutting.
u
f


sin


sin
u
t 
cos 
 cos
