Orthogonal and Oblique cutting

Pure orthogonal cutting

Causes of chip flow deviation
Restricted cutting edge
Effect of tool nose radius
Effect of inclination angle
Effective rake angle
Effects of oblique cutting

 chip flow deviates from orthogonal plane

 affects transverse force irrespective of Φ
 affects effective rake, hence forces
 affects chips cross section and shape
 force analysis becomes complex
 affects tool life
Mechanism of chip formation in machining ductile materilas
Mechanism of chip formation in machining brittle materials
Orthogonal machining
Kronenberg’s model
Cutting strain
Built-up-edge formation
Characteristics of BUE
Need and purpose of chip-breaking

Principles of chip-breaking
Self breaking of chips
Forced chip breaking
Parallel step type in-built chip breaker
Chip breakers in solid HSS tools
Cutting force component
Cutting forces in drilling
Cutting forces in milling
Merchant circle diagram
For brittle material
For ductile materials
Friction force and normal force
Relationship between velocities

V = Cutting velocity

Vs = Shear velocity

Vc = Chip velocity
Question: In an orthogonal cutting test with a tool of rake angle 10º, the following
observations were made:
Chip-thickness ratio = 0.3
Horizontal component of the cutting force = 1290 N
Vertical component of the cutting force = 1650 N
From the Merchant’s theory, calculate the various components of the cutting forces and
the coefficient of friction at the chip-tool interface.

Ans: F = 1848.94 N
N = 983.88 N
µ = 1.8792
β = 62°
R = 2049.42 N
Fs = 740.63 N
Ns = 1959.10 N
Measurement of cutting forces
Turning dynamometer
Drilling dynamometer
Milling dynamometer
Grinding dynamometer