THEORY OF METAL CUTTING
(17ME4705/B)
(CUTTING FORCES)
By
Dr Ch Nagaraju
Professor
Mechanical Engineering Department
VR Siddhartha Engineering College
Vijayawada – 520007
COURSE OUTCOMES
CO1: Explain the ASA, ORS and NRS systems
of tool geometry and derive their
interrelationships.
CO2:Develop the relations for chip reduction
coefficient, shear angle, shear strain, forces,
power and specific energy with orthogonal
cutting.
CO3:Analyze thermal aspects and tool wear
relationships in orthogonal cutting.
CO4:Select cutting tool material for
improving tool life and understand the
mechanics of multipoint machining.
UNIT II
Mechanics of Machining Processes: Orthogonal and
Oblique cutting, Types of chips, chip-breakers, Chip
reduction coefficient, shear angle, shear strain,
Built- Up-Edge and its effect in metal cutting.
Merchant’s analysis of metal cutting process:
Various forces, power and specific energy in
cutting, Problems on Tool Geometry and Mechanics
of Machining.
Theories of Metal Cutting: Ernst & Merchant,
theory, Modified Merchant’s theory, Lee & Shaffer
Theory, Chip-tool Natural Contact Length – Hahn’s
Analysis Stress distribution at Chip-Tool Interface –
Zorev’s Analysis, Machining with controlled contact
cutting, Chip breakers.
VELOCITY RELATIONS
the cutting velocity (V), which is the velocity
of the tool relative to the work and directed
parallel to FP
the chip velocity (VC), which is the velocity of
the chip relative to the tool and directed
along the tool face
the shear velocity (V ), which is the velocity
S
of the chip relative to the workpiece and
directed along the shear plane.
VELOCITY RELATIONS
VELOCITY RELATIONS
VELOCITY RELATIONS
VELOCITY RELATIONS
CUTTING FORCE ANALYSIS -
ASSUMPTIONS
1. The tool is perfectly sharp and there is no contact along the
clearance face.
2. The shear surface is a plane extending upward from the cutting
edge.
3. The cutting edge is a straight line extending perpendicular to the
direction of motion and generates a plane surface as the work
moves past it.
4. The chip does not flow to either side (plane strain).
5. The depth of cut is constant.
6. The width of the tool is greater than that of the workpiece.
CUTTING FORCE ANALYSIS –
ASSUMPTIONS
7. The work moves relative to the tool with uniform
velocity.
8. A continuous chip is produced with no built-up edge.
9. The shear and normal stresses along shear plane and
tool are uniform (strength of materials approach). Such
an ideal two-dimensional cutting operation is referred
to as orthogonal cutting.
CUTTING FORCE ANALYSIS
CUTTING FORCE ANALYSIS
When the chip is isolated as a free body,
consider only two forces—the force between the
tool face and the chip (R) and the force between
the workpiece and the chip (R′). For equilibrium
these must be equal
R = R′
The forces R and R′ are conveniently resolved
into three sets of components
1. in the horizontal and vertical direction, FP and FQ
2. along and perpendicular to the shear plane, FS and
NS
3. along and perpendicular to the tool face, FC and
NC
MERCHANT CIRCLE
RELATION BETWEEN FS ,NS IN FP AND FQ
RELATION BETWEEN FS ,NS IN FP AND FQ
RELATION BETWEEN FC ,NCIN FP
AND FQ
RELATION BETWEEN FC,NCIN FP AND FQ
IMPORTANT RELATIONS
Area of the shear plane As: b*t /sinsh
Coefficient of friction µ = Fc/Nc
Mean shear stress τ= Fs/As
Normal stress σ = Ns/As
Total work done in cutting WC = FP * V
Work done in shear Ws = FS* VS
Work done in Friction Wf = FC* VC
Total work done = Work done in shear + Work done in
Friction
PROBLEM_1
In orthogonal cutting of a material the feed
force is 80kgf and cutting force is 150 kgf.
Given the chip thickness ratio as 0.3 and
rake angle as 80 Calculate a) Compressive
and shear force on shear plane b) coefficient
of friction of the chip on the tool face.
Sol : shear angle =
FP=150Kgf FQ=80kgf
Compressive force on shear plane NS
Shear force on shear plane FS
Coefficient of friction µ = Fc/Nc
