Metal Cutting Process
SPRIN G 2026
N U S R AT A H M A D
L EC T UR ER , IPE
A M ER I C A N I N T E R N AT I O N A L U N I V E R S I T Y B A N G L A D ES H
Theory of Merchant
Theory of Merchant
Relationship between shear and chip thickness ratio
Relationship between shear and chip thickness ratio
Terminology
• Shear force (𝐹𝑠 )
• Normal shear force (𝐹𝑛 )
• Friction force (F)
• Normal friction force (N)
• Cutting force (𝐹𝑐 )
• Thrust force (𝐹𝑡 )
• Rake angle (𝛼)
• Frictional angle (𝛽)
• Shear angle (𝜙)
• Cutting velocity (𝑉)
• Chip velocity (𝑉𝑐 )
• Shear velocity (𝑉𝑠 )
Terminology
Shear force, 𝐹𝑠 = 𝐹𝑐 𝐶𝑜𝑠𝜙 − 𝐹𝑡 𝑆𝑖𝑛𝜙
Normal to shear force, 𝐹𝑛 = 𝐹𝑐 𝑆𝑖𝑛𝜑 + 𝐹𝑡 𝐶𝑜𝑠𝜙
Friction force, 𝐹 = 𝐹𝑐 𝑆𝑖𝑛𝛼 + 𝐹𝑡 𝐶𝑜𝑠𝛼
Normal force, 𝑁 = 𝐹𝑐 𝐶𝑜𝑠𝛼 − 𝐹𝑡 𝑆𝑖𝑛𝛼
𝐹𝑡 +𝐹𝑐 tan 𝛼
Friction angle, 𝛽 = tan−1
𝐹𝑐 −𝐹𝑡 sin 𝛼
𝑟 cos 𝛼
Shear angle, 𝜑 = tan−1
1−𝑟 sin 𝛼
Power
•Power (or energy consumed per unit time) is the product of force and velocity.
Power at the cutting spindle:
•Power is dissipated mainly in the shear zone and on the rake face:
•Actual Motor Power requirements will depend on machine efficiency E (%):
Cutting Forces and Power measurement
Measuring Cutting Forces and Power
• Cutting forces can be measured using a force
transducer, a dynamometer or a load cell mounted
on the cutting-tool holder
• It is also possible to calculate the cutting force from the
power consumption during cutting (provided
mechanical efficiency of the tool can be determined)
• The specific energy (u) in cutting can be used to
calculate cutting forces
9
Problem-1
The following observations were made during
an orthogonal metal cutting operations
Tool rake angle =10°
Co-efficient of friction = 0.85
Chip thickness = 2.5 𝑚𝑚
Width of cut = 15 𝑚𝑚
Feed = 1.5 mm/rev
Shear strength = 650 𝑁/𝑚22
650 N/mm
Cutting velocity = 40m/min
Determine the following:
a) Chip thickness ratio b) Shear angle c)
Shearing force d) Friction angle e) cutting
force f) Power consumed
Problem-1
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Problem-1
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Problem-1
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Problem-1
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Problem-2
In an orthogonal cutting operation, the
following data have been observed:
Uncut chip thickness, 𝑡 = 0.127 𝑚𝑚
Width of cut, 𝑏 = 6.35 𝑚𝑚
Cutting speed, 𝑉 = 2 𝑚/𝑠
Rake angle, 𝛼 = 10°
Cutting force, 𝐹𝑐 = 567 𝑁
Thrust force, 𝐹𝑡 = 227 𝑁
Chip thickness, 𝑡𝑐 = 0.228 𝑚𝑚
Determine shear angle, friction angle, shear
stress along the shear plane , power for the
cutting operation and chip velocity.
Problem-2 𝑟 cos 𝛼
Shear angle, 𝜑 = tan −1
1−𝑟 sin 𝛼
𝑡 0.127
Chip thickness ratio, 𝑟 = = = 0.557
𝑡𝑐 0.228
Rake angle, 𝛼 = 10°
Shear angle, 𝜑 = 31.25°
𝐹𝑡 +𝐹𝑐 tan 𝛼
Friction angle, 𝛽 = tan−1
𝐹𝑐 −𝐹𝑡 sin 𝛼
Given the cutting and thrust forces are 567 and 227 N
Friction angle, 𝛽 = 32.63°
Shear force, 𝐹𝑠 = 𝐹𝑐 𝐶𝑜𝑠𝜙 − 𝐹𝑡 𝑆𝑖𝑛𝜙; 𝐹𝑠 = 367 𝑁
𝐹𝑠 367×0.519
Shear stress, 𝜏 = = = 236.5 𝑁/𝑚𝑚2
𝐴𝑠 6.35×0.127
Problem-2
𝐹𝑐 𝑉 2
Cutting Power = = 567 × = 1.134 𝑘𝑊
1000 1000
𝑉𝐶
Chip velocity, =𝑟
𝑉
𝑉𝑐 = 𝑟𝑉 = 2 × 0.557 = 1.114 𝑚/𝑠
