ME 392Q Manufacturing Processing: Unit Processes University of Texas at Austin 1
PHYSICS OF MACHINING
o Cutting ubiquitous manufacturing process
o Formulate model of cutting physics to predict tool forces dependency on ! Materials ! Cutting speed ! Geometry ! Conditions
Approach: Merchants cutting model o Kinematics: relate geometric & motion variables o Dynamics: stationary system (quasi- equilibrium) ! Balance tool forces ! Power considerations o Assembly
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Merchants cutting model
o Simplifying assumptions ! Thin shear zone (!w -> 0) ! Type II, continuous chip ! Orthogonal cutting (edge perpendicular to cutting velocity) ! Perfectly sharp cutting edge ! Plastic flow at shear zone ! Shearing in plane ! Incompressible chip
tool workpiece flank or relief rake face chip v shear zone
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o Weakness of assumptions ! Dull cutter ! Deformation ZONE, not line ! Metals strain harden ! Most cutting is oblique (edge not perpendicular to cutting velocity)
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Geometry near shear zone
tool rake face chip v shear line uncut chip L s h ! " h c v c y x h cx " # !/2 - "
o h depth of cut o L s length of shear zone o " shear zone angle o h c thickness of cut chip o # rake angle o v velocity, uncut chip o v c velocity of chip
h cx = L s cos ! + h tan "
! h cx = h cos"cos# + sin# sin" sin"cos# = h c cos#
note: h = L s sin !
! h c = h cx cos"
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Definition: Cutting ratio r = h/h c
! r = h h c = sin" cos"cos# + sin# sin" = sin" cos " $# ( )
! = 1 cot "cos# + sin#
< 1, for small ", #
Incompressible chip:
" final volume = initial volume
" dV f /dt = dV i /dt
" v h b = v c h c b
! b out of plane thickness
" chip velocities: v c < v
! v c v = h h c = r <1
6 Geometry
tool rake face chip v shear zone uncut chip h ! " h c v c y x # L c
o L c length of tool-chip contact zone o h depth of cut o L s length of shear zone o " shear zone angle o h c thickness of cut chip o # rake angle o $ relief angle o v velocity, uncut chip o v c velocity of chip
7 Tool forces: Free Body Diagram, Chip chip ! " y x F c F s R F n F f R!
o F c compressive force, workpiece on chip o F s shear force, workpiece on chip o R resultant force, F c & F s
o F n normal force, tool on chip o F f friction force, tool on chip o R resultant force, F n & F f
o " shear zone angle o # rake angle
Assumptions: o stationary system (steady velocities) " dv/dt = dv c /dt = 0 (no accelerations)
" ! F = 0 (quasi-equilibrium)
o R & R act along same line (no moments)
8 chip ! " y x F c F s R F n F f R! s c f n ! #/2 $" !
angle = #/2 ! (#/2 - ") = " $ !
equilibrium:
! F s = 0 ! F c = 0
F s - (F n ) s - (F f ) s = 0 F c + (F n ) c - (F f ) c = 0
F s = (F n ) s + (F f ) s F c = - (F n ) c + (F f ) c
9 Constitutive Equations
o Tool-chip rubbing interface:
Coulomb friction F f = F n
Friction angle: %
= F f /F n = tan %
o Shear zone:
Rigid-Perfectly Plastic material
all yielding, stress & = & s
F n F f R! ! stress ! strain " ! s " p stress ! strain " ! s " e " p F f = F n = F n tan % F s = & s A = & s L s b = & s bh/sin !
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angle = " $ !
(F n ) c = F n sin (" $ !) = - F n sin (! $ ")
(F n ) s = F n cos (" $ !)
(F f ) c = F f cos (" $ !)
(F f ) s = F f sin (" $ !) = - F f sin (! $ ")
chip ! " y x F c F s R F n F f R! s c f n ! #/2 $" ! F n F f s c f n ! "# ! "# (F n ) c (F n ) s (F f ) s (F f ) c ! "#
11 o Combine: (F n ) c = - F n sin (! $ ") (F n ) s = F n cos (! $ ")
(F f ) c = F f cos (! $ ") = F n cos (! $ ") (F f ) s = - F f sin (! $ ") = - F n sin (! $ ")
o Substitute: F s = (F n ) s + (F f ) s = F n [cos(! $ ") sin(! $ ")]
o Solve: ! F n = " s bh sin# 1 cos(# $%) $sin(# $%)
o Substitute: F c = -(F n ) c +(F f ) c = F n [sin(! $ ")+ cos(! $ ")]
! F c = " s bh sin# sin(# $% + &) cos(# $% + &) = " s bh sin# tan(# $% + &)
o Obtain resultant force:
! R = F s 2 + F c 2 = " s bh sin# 1+ tan 2 (# $% + &) = " s bh sin# sec 2 (# $% + &)
! R = " s bh sin# 1 cos(# $% + &)
Note: " is still unknown
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Power in:
P in = F cut v
o F c compressive force, workpiece on chip o F s shear force, workpiece on chip o R resultant force o F cut cutting force, in x-direction o F thrust thrust force, in y-direction