Metal Cutting

Machining: A term applied to all material-removal processes. Machining processes are capable of producing more precise dimensions and smooth surface finishes than all other manufacturing processes. They are performed after other processes, which create the general shape of the parts. Machining then provides the final geometry, dimensions and finish. Metal cutting: a thin layer of excess metal (chip) removed from a workpiece by a wedge-shaped single-point or multipoint cutting tool with defined geometry through a process of extensive plastic deformation. Abrasive processes: material removal by the action of hard, abrasive particles that are usually in the form of a bonded wheel. Each single abrasive particle acts like a single-point cutting tool. Since the geometry of particular particle is not defined, abrasive processes are referred to as machining with geometrically undefined tools. Non-traditional processes: machining with electrical, optical or chemical sources of energy

Requires Workpiece Cutting tool harder than the workpiece Relative motion between the workpiece and the tool The shavings removed during cutting the metal are called chips Single point cutting tool One dominant cutting edge Turning, boring, shaping Multiple cutting edges More than one cutting edge Drilling, tapping, reaming Milling, broaching, sawing Grinding

Older misconception (Mallock & Reuleux, 1900) Metal cutting is a fracture process, involves crack formation and propagation (similar to splitting of wood)

Present day theory Metal cutting is shearing process and involves plastic flow & usually there is no crack formation at the tool tip.

P.M.Agrawal

Theory of Metal Cutting

Page 1 of 3

Tool is wedge shaped Cutting edge intersection of two plane surfaces Cutting velocity represented by a vector meeting the cutting edge at a point Tool geometry: refers to some specific angles or slope of the salient faces and edges of the tools at their cutting point Tool geometry is spatial relationship between Velocity vector Cutting edge Two surface which intersect to define the cutting edge

Orthogonal and Oblique cutting

Orthogonal cutting Oblique cutting

Cutting edge of the tool perpendicular to the direction of relative tool-workpiece motion Direction of chip flow normal to the cutting edge of the tool Only two components of force Cutting force Thrust force

2D Cutting Widely used in theoretical and experimental work

Cutting edge of the tool inclined at an acute angle to the direction of tool feed or workpiece feed Direction of chip flow at an angle with the normal to the cutting edge of the tool, known as chip flow angle Three components of force Cutting force Thrust force or feed force Radial force 3D Cutting Since cutting edge is oblique, shear force acts over a larger area. This increases tool life.

P.M.Agrawal

Theory of Metal Cutting

Page 2 of 3

++=90 Where is clearance angle is wedge angle is rake angle

Rake face: Face on which chip flows Rake angle (): Angle between rake face of the tool and normal to the new workpiece surface. always at the top side of the tool Ease of machining and chip flow Clearance face or flank: Surface ground back to clear the machine workpiece surface. Clearance angle (): Angle of inclination of clearance or flank surface from the finished surface No role in the process of chip removal Must be positive (3 to 15 depending upon tool-workpiece material and the type of operation) Important since rubbing of the tool flank with the machined surface will cause loss of energy. Also damages both tool and the job surface. Wedge angle: Included angle between the rake face and the flank Determines resisting force of the cutting edge as well as the strength of the tool tip.

Rake angle - Rake angle may be positive, or negative or even zero

P.M.Agrawal

Theory of Metal Cutting

Page 3 of 3