Proses Pemesinan

Material Removal Processes

Mekanisme Pembentukan Geram

M. Oktaviandri

Universitas Batam
2013
Intro

Mulanya diperkirakan geram terbentuk karena adanya retak mikro (micro

crack) timbul pada benda kerja tepat di ujung pahat pada saat pemotongan
dimulai.

Dengan bertambahnya tekanan pahat, retak tersebut menjalar ke depan

sehingga terjadilah geram (Gambar 3.1).

Sebenarnya dapat dijelaskan dengan analogi tumpukan kartu (Gambar 3.2)

Komponen Gaya Pembentukan Geram

Teori Merchant  model pemotongan sistem tegak (ortogonal system),

dengan asumsi:

- Mata potong pahat sangat tajam sehingga tidak menggosok atau

menggaruk benda kerja
- Deformasi terjadi hanya dalam dua dimensi
- Distribusi tegangan yang merata pada bidang geser dan gaya aksi dan
reaksi pahat terhadap bidang geram adaah sama besar dan segaris (tidak
menimbulkan momen kopel).
Ada tiga cara menentukan gaya total
1. Ditinjau dari deformasi material
2. Dengan dinamometer
3. Dari gaya yg beraksi pada bidang geram
Dengan demikian maka rumus gaya potong adalah:
Daya Pemotongan dan Efisiensi Pemotongan
 Chip Formation
The fundamental mode of material removal in cutting is by chip formation. The
stages involved in chip removal are: workpiece moves relative to a cutting
edge, which then penetrates the surface, the workpiece material near the
surface is sheared by the cutting edge to form a chip.
The types of chips produced significantly
influences surface finish and integrity, as well as
the overall cutting operation. Types of chips
commonly produces are:
– Continuous chips;
– Built-up edge;
– Serrated (segmented);
– Discontinuous.
 Continuous chips
Continuous chips are usually formed at high rake
angles and/or high cutting speeds. Continuous
chips are less likely to form if the workpiece is
brittle. A good surface finish is generally produced.
However, continuous chips are not always
desirable, particularly in automated machine tools,
because they tend to get tangled around the tool,
and the operation has to be stopped to clear away
the chips. This problem can be alleviated by using
chip breakers.
 Built-up edge chips (BUE)
A Built-up edge (BUE) may form at the tip of the tool during
cutting. The BUE consists of layers of material from the
workpiece that are gradually deposited on the tool. The
BUE then becomes unstable and eventually breaks up.
Some BUE material is carried away on the tool side of the
chip; the rest is deposited randomly on the workpiece
surface. BUE is most likely to form if the workpiece is highly
plastic. BUE can result in the formation of a poor surface
finish. The tendency for BUE to form can be reduced by
increasing the rake angle and therefore decreasing the
depth of cut.
 Discontinuous chips
Discontinuous chips consist of segments
that may be firmly or loosely attached to
each other. These chips occur when
machining hard brittle materials such as cast
iron. Brittle failure takes place along the
shear plane before any tangible plastic flow
occurs. Discontinuous chips will form in
brittle materials at low rake angles (large
depths of cut).