Manufacturing Process-II

Lecture 5 & 6
Force Relationship in Metal Cutting

Subject:19MEE215- Manufacturing Technology-II

Class: III Sem B.Tech –Mechanical
 Last Class Overview
• Difference between Orthogonal & Oblique cutting
• Chip Thickness Ratio

• Shear Plane angle Determination

r cos 
tan  
1  r sin 
• Velocity Relationship in Metal cutting

vc  v  r
v sin  v cos 
vc  vs 
cos(   ) r  Sin  
  cos(   )
 Cos ( -  ) 
 Today’s Class Overview
• Forces in Metal cutting
– Cutting Force
– Thrust Force

– Shear Force
– Normal to the shear force
– Friction force
– Normal to the Friction Force

• Force Relationship- Merchant Circle Diagram

– Frictional Force System
– Shear Force System
 Need of studying “Forces in Machining”
• Knowledge of cutting forces needed for
– Estimation of power requirements
– Machine tool design e.g. static/dynamic
stiffness
– Part accuracy e.g.- tool- work piece deflection
 Forces in Metal Cutting

F, N, Fs, and Fn cannot be directly measured

Forces acting on the tool that can be measured:
– Cutting force Fc and Thrust force Ft
5
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 work piece
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
Fc = Horizontal cutting force exerted
by the tool on the work piece
Ft = Vertical force which helps in
holding the tool in position and acts on
the tool nose
1. Merchant circle is useful to determine the relation between the
various forces & angles.

2. In the diagram two force triangles have been combined & R &
R’ together have been replaced by R

3. The force R can be resolved into two components Fc & Ft

4. Fc & Ft can be determined by force dynamometers

5. The rack angle (α ) can be measured from the tool & forces F &
N can then be determined

6. The shear angle (Ф) can be obtained from it’s relation with chip
reduction coefficient

7. Now Fs & Fn can also be determined

The procedure to construct a Merchant’s
circle diagram

Chip α
Tool
Fs
Fc ∅ Clearance Angle

Work
Fn
Ft R
α

β
N

79
Merchant’s Circle Diagram

Chip α
Tool
Fs
Fc ∅ Clearance Angle
(β - α)
Work
Fn
Ft R
α

β
N

78
 Relationship of various forces acting on the chip with the horizontal and
vertical cutting force from Merchant circle diagram
Frictional Force System
D α
Chip
α Tool
C Fs
Fc ∅ Clearance Angle
(90-α) α
E α Fc O
(β - α)
(β - α)
(90-α) G Work
Fn
Ft R Ft R
α α

α F F

β β
B N N
A

82
 D
α
C
= ED + GB
(90-α)
E
α
O
From triangle BEG we have
α Fc
(β - α)
(90-α) G
≫ 𝐺𝐵=𝐸𝐵 𝐶𝑜𝑠 𝛼=𝐹 𝑡 𝐶𝑜𝑠 𝛼
Ft R
α
From triangle OED we have
α F
Sin
β
B N 𝐸𝐷=𝑂𝐸 𝑆𝑖𝑛𝛼
A 𝐸𝐷=𝐹 𝑐 𝑆𝑖𝑛𝛼

𝐹 =𝐹 𝑐 𝑆𝑖𝑛𝛼+ 𝐹 𝑡 𝐶𝑜𝑠 𝛼

11
 D
α N
C
OD - GE
(90-α)
E
α
O
From triangle BEG we have
α Fc
(β - α)
(90-α) G Sin ≫ GE
Ft R
α
From triangle OED we have
α F
Cos
β
B N O
A O

12
Relationship of various forces acting on the chip with the horizontal and
vertical cutting force from Merchant circle diagram
Shear Force System
B
Chip α
α Tool
A Fs
Fs Fc Clearance Angle
(90-∅) Fc ∅
C ∅ (β - α)
∅ O
(β - α) Work
Fn
(90-∅) Ft R
Fn D
α
Ft R
α
F
∅
β
N

83
Relationship of various forces acting on the chip with the horizontal and
vertical cutting force from Merchant circle diagram
Shear Force System
B
= OB - CD
α
A

(90-∅) Fc
Fs 𝑓𝑟𝑜𝑚𝑡𝑟𝑖𝑎𝑛𝑔𝑙𝑒 𝑂𝐵𝐶
C ∅
∅ O
(β - α) 𝑂𝐵
(90-∅) 𝐶𝑜𝑠 𝛼=
Fn D 𝑂𝐶
Ft R 𝑂𝐵=𝑂𝐶 ∗ 𝐶𝑜𝑠 ∅ = 𝐹 𝑐 cos ∅
α

∅
𝑓𝑟𝑜𝑚𝑡𝑟𝑖𝑎𝑛𝑔𝑙𝑒 𝐸𝐶𝐷

E 𝐶𝐷
𝑆𝑖𝑛 ∅ =
𝐶𝐸

Sin

𝐹 =𝐹 𝑐 𝐶𝑜𝑠 ∅ − 𝐹 𝑡 𝑆𝑖𝑛 ∅

83
Relationship of various forces acting on the chip with the horizontal and
vertical cutting force from Merchant circle diagram
Shear Force System
B 𝐹 𝑛= 𝐴𝐸 = 𝐴𝐷 + 𝐷𝐸
α
A ¿ 𝐵𝐶 + 𝐷𝐸
Fs
(90-∅) Fc
∅
C
∅ O 𝑓𝑟𝑜𝑚𝑡𝑟𝑖𝑎𝑛𝑔𝑙𝑒 𝑂𝐵𝐶
(β - α)
(90-∅) 𝐵𝐶
Fn D 𝑆𝑖𝑛 ∅ =
𝑂𝐶
Ft R
α
𝐵𝐶=𝑂𝐶𝑆𝑖𝑛 ∅
∅
𝐵𝐶=𝐹 𝑐 𝑆𝑖𝑛 ∅

E 𝑓𝑟𝑜𝑚𝑡𝑟𝑖𝑎𝑛𝑔𝑙𝑒 𝐸𝐶𝐷
𝐷𝐸
𝐶𝑜𝑠 𝛼=
𝐶𝐸
𝐷𝐸=𝐶𝐸 𝐶𝑜𝑠 ∅
¿ 𝐹 𝑡 𝐶𝑜𝑠 ∅

𝐹 𝑛= 𝐹 𝑐 𝑆𝑖𝑛 ∅ + 𝐹 𝑡 𝐶𝑜𝑠 ∅
83
 Relationship of various forces acting on the chip with the
horizontal and vertical cutting force from Merchant circle diagram

Chip α
Tool
Fs
Fc Clearance Angle
∅
(β - α)
Work
F  FC sin   Ft cos 
Fn

Ft R
N  FC cos   Ft sin 
α
FS  FC cos   Ft sin 
F
FN  FC sin   Ft cos 
β FN  FS tan(     )
N

Ft = R Sin (β-α)
Fc = R Cos (β –α)
84
 Coefficient of Friction
Coefficient of friction between tool and chip:
F
 
N
Friction angle related to coefficient of friction as follows:

  tan 
The ratio of F to N is the coefficient of friction, μ, at the tool-chip interface,
and the angle β is the friction angle.
F Ft  Fc tan 
Coefficien t of friction,   
N Fc  Ft tan 

The coefficient of friction in metal cutting generally ranges from about 0.5
to 2. 17