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MODULE
II
Manufacturing Processes:
Theory of Metal Cutting &
Machine Tools
Lecture Notes
Joyjeet Ghose
Chip
Formation
Email: joyjeetghose@gmail.com
Senior Lecturer,
Department of Production Engineering,
Birla Institute of Technology, Ranchi
Chip Formation
Regardless of the tool being used or the metal being cut, the chip forming
pprocess occurs by
y a mechanism called pplastic deformation. This
deformation can be visualized as shearing. That is when a metal is
subjected to a load exceeding its elastic limit.
This action, shown in Figure is similar to the action that takes place when
a deck of cards is given a push and sliding or shearing occurs between the
individual cards.
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Types of chip
Discontinuous or segmented
Continuous
Continuous with a built-up edge.
Types of chip
FIGURE : Various chips produced in turning: (a) tightly curled chip; (b) chip hits workpiece and
breaks; (c) continuous chip moving away from workpiece; and (d) chip hits tool shank and breaks
off. Source: G. Boothroyd, Fundamentals of Metal Machining and Machine Tools.
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Continuous Chip
During cutting of ductile materials a continuous ribbon type chip is
produced.
The pressure of the tool makes the material ahead of cutting edge
deformed plastically.
p
y
It generally suffers compression and shear. The material then slides over
the tool rake face for some distance and then leaves the tool.
Factors favorable to its formation are ductile metals, such as mild steel,
copper etc., fine feed, high cutting speed, large rake angle, keen cutting
edge, smooth tool face and efficient lubrication system.
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Discontinuous Chip
Discontinuous or segmented chips are produced when brittle metal such as cast
iron and hard bronze are cut or when some ductile metals are cut under poor
cutting conditions.
The chip formation mechanism in this case is quite different from that in the case
of ductile materials. Even a slight plastic deformation produced by a small
advance of the cutting edge into the job leads to a crack formation in the
deforming zone. With further advance of the cutting tool, the crack travels and a
small lump of material starts moving up the rake face. The force and constraints
in the motion acting on the lump make the crack propagate towards the surface,
th s a small fragment of the chip gets detached.
detached As the tool moves
mo es further,
f rther
and thus
this sequence is repeated.
Conditions tending to promote discontinuous chip formation include: brittle
metal, greater depth of cut, low cutting speed and small rake angle.
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Chip Breakers
A continuous chip flows away from the work at high speed. If this chip is
allowed to continue, it may wrap around the tool post, the workpiece, the
chuck, and perhaps around the operators arm. Not only is the operator in
danger of receiving a nasty laceration, but if the chip winds around the
workpiece and the machine, he must spend considerable time in removing it.
A loss of production will be encountered. Therefore it is imperative that this
chip be controlled and broken in some manner. Hence chip breakers are used
to break up the long continuous chip in small pieces.
Chip breakers may be of the following types:
1 Step type: A step is ground on the face of the tool along the cutting edge.
edge
1.Step
2.Groove type: A small grove is ground behind the cutting edge.
3.Clamp type: A thin carbide plate or clamp is brazed or screwed on the face
of the tool
Chip Breakers
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Tool wear
Cutting tools are subjected to extremely severe cutting conditions such as:
1. metal to metal contact with chip and work
2. very high stress
3 very high temperature
3.
4. very high temperature gradients
5. very high stress gradients
Because of all the above-mentioned factors, the tool-chip interface exhibit
the type of wears found. As tool wear progresses, cutting forces increase
and vibrations increase. Tool tip softens and flows plastically and gets
blunt edge which will result in further progressing of plastic deformation
from the tool tip to the interior.
Cutting tool life is one of the most important economic considerations in
metal cutting.
Conditions giving a very short tool life will not be economical because
tool-grinding,
l i di indexing,
i d i andd tooll replacement
l
costs will
ill be
b high.
hi h
On the other hand, the use of very low speeds and feeds to give long tool
life will not be economical because of the low production rate.
Efforts are thus made to understand the behavior of the tool, how it
physically wears, the wear mechanisms, and forms of tool failure.
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
Crater Wear
Typically, crater wear occurs on the rake face of the tool. It is essentially the erosion
of an area parallel to the cutting edge. This erosion process takes place as the chip
being cut, rubs the top face of the tool. Under very high-speed cutting conditions and
when machining tough materials, crater wear can be the factor which determines the
life of the tool. However, when tools are used under economical conditions, the edge
wear and not the crater wear is more commonly the controlling factor in the life of
the tool. Crater wear is caused mainly by diffusion and adhesion.
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Wear Mechanisms
Four basic wear mechanisms is categorized as::
Abrasion: Because hard inclusions in the workpiece microstructure plow into
the tool face and flank surfaces, abrasion wear predominates at relatively low
cutting temperatures. The abrasion resistance of a tool material is proportional
to its hardness.
hardness
Adhesion: Caused by formation and subsequent destruction of minute welded
junctions, adhesion wear is commonly observed as built-up edge (BUE) on
the top face of the tool. This BUE may eventually disengage from the tool,
causing a crater like wear. Adhesion can also occur when minute particles of
the tool surface are instantaneously welded to the chip surface at the tool chip
interface and carried awayy with the chip.
p
Diffusion: When a metal is in sliding contact with another metal and the
temperature at their interface is high, conditions may become right for the
alloying atoms from the harder metal to diffuse into the softer matrix; thereby
increasing the latters hardness and abrasiveness. On the other hand atoms
from the softer metals may also diffuse into harder metal, thus weakening the
surface layer of the latter to such an extent that particles on it are dislodged
andd are carried
i d away by
b flowing
fl i chip
hi material.
t i l Because
B
off high
hi h temperatures
t
t
and pressures in diffusion wear, micro transfer on an atomic scale takes place.
The rate of diffusion increases exponentially with increases in temperature. .
Oxidation: At elevated temperature, the oxidation of the tool material can
cause high tool wear rates. The oxides that are formed are easily carried away,
leading to increased wear.
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
17/07/2008
Tool Failure
A tool that no longer performs the desired functions is said to have failed and
hence reached the end of its useful life. At such an end point the tool is not
necessarily unable to cut the workpiece but is merely unsatisfactory for the
purpose required. The tool may be resharpened and used again.
Following are the some of the possible criterion for limiting the tool life:
Flank wear: Flank wear is not of uniform width. It is larger at or near the tow
ends of the active portions of the side cutting edge. At the nose portion the chip
flow is rather complicated and wearing conditions severe. At the rear portion of
the flank wear land, groove or notch gets formed on account of accelerated wear.
It has been suggested that accelerated wear is caused by abrasion and metal
transfer, enhanced by chemical interaction with the surrounding atmosphere. The
idth of the wear
ear land is maximum
ma im m at the rear end of the flank land.
land According
width
to ISO recommendation, following wear land criterion are appropriate for tool
made from different materials, both roughing and finishing cuts: VB=0.3mm;
VBmax=0.6mm.
KM
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Tool life
Tool life represents the useful life of the tool, expressed generally in time
units from the start of a cut to some end point defined by failure criterion.
A common method of forecasting tool wear is to use Taylors equation; his
study on tool life was done in 1907
1907.
Taylor thought that there is an optimum cutting speed for
best productivity. This is reasoned from the fact that at low
cutting speeds, tools have higher life but productivity is low,
and at higher speeds the reverse is true. This inspired him to
check upp the relationshipp of tool life and cuttingg speed.
p
Based on the experimental work he proposed the formula for
Frederick W. Taylor 1856-1915
tool life.
Taylors Empirical Equation: VT n =C
Where, T = tool lifetime; usually in minutes
V = cutting velocity, m/min
g velocityy for 1 minute of elapsed
p
time before reaching
g the wear limit of
C = constant;; the cutting
the tool
n = constant which is considered a characteristic of the tool material, called tool life index.
Note: at T = 1 minute, C becomes equal to the cutting speed
Each combination of workpiece, tool material and cutting condition has its own n and C
values, both of which are determined experimentally
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
17/07/2008
Work
materials
Carbide
Cera
mic
Sl
No
Tool Materials
Values of
n
HSS
0.08 - 0.2
Cemented
Carbide
0 3 - 0.49
0.3
0 49
Ceramic
0.5 - 0.7
Carbon steel
Cast Iron
30 60
Stainless
Steel
20 35
120 200
Titanium
10 20
100 150
Tungsten
120 160
400 - 600
FIGURE : Effect of workpiece microstructure on tool life in turning. Tool life is given in terms of
the time (in minutes) required to reach a flank wear land of a specified dimension. (a) ductile
cast iron. (b) Steels, with identical hardness. Note the rapid decrease in tool life as the cutting
speed increases.
Source Manufacturing Processes for Engineering Materials, 4th edition, Kalpakjian, Schmid,
Prentice Hall 2003
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
10
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Tool life
Tool life curves are usually plotted on log-log paper or are plotted taking log of the
equation, from which we can easily determine the exponent n.
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Tool-Life Curves
Tool life
To account for the effect of feed and depth of cut a generalized
Taylors equation is formed:
V=
Where,
S= feed in mm/min
t= depth of cut mm
Cv
1
m
T s yv t xv
Cv =
1
= Taylors exponent n
m
xv
xv
yv
12
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Economics of machining
The efficiency of machine tools increases as cutting speeds increase, but
tool life is reduced. The main objective of metal-cutting economics is to
achieve the optimum conditions, that is, the minimum cost while
considering the principal individual costs: machining cost,
cost tool cost,
cost
tool-changing cost, and handling cost.
FIGURE :Graphs showing (a) cost per piece and (b) time per piece in machining. Note the optimum
speeds for both cost and time. The range between the two optimum speeds is known as the highefficiency machining range
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
13
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Economics of machining
The two most important parameter in in economics of machining are
the minimum cost per part and the maximum production rate. The total
cost per piece consists of four items:
C p = Cm + Cs + Cl + Ct
Cm = Tm ( Lm + Bm )
Where Tm is the machining time per piece, Lm is the labor cost of the
operator per hour, Bm and is the burden rate, or overhead charge of the
machine including depreciation, indirect labor etc.
Economics of machining
The setup cost, Cs is a fixed amount per piece. The loading, unloading,
and machine handling cost, Cl is given by:
Cl = Tl ( Lm + Bm )
Where is the time required in loading and unloading the part, changing
speed and feed etc. The tooling cost, Ct is expressed as:
Ct =
1
Tc ( Lm + Bm ) + Tg ( Lg + Bg ) + Dc
Np
Wh
i the
th number
b off parts
t machined
hi d per tool
t l grind;
i d Tc is
i the
th time
ti
Where
Np is
required to change the tool; Tg is the time required to grind the tool; Lg
is the labor cost of the tool grinder operator per hour, Bg is the burden
rate of tool grinder per hour; and Dc is the depreciation of the tool in
rupees per grind.
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Economics of machining
The time needed to produce one part is
Tc
Np
Tp = Tl + Tm +
L LD
=
fN
fV
Tm =
C
T =
V
1
n
Economics of machining
The number of pieces per tool grind is
Np =
Therefore from the above equations:
Np =
T
Tm
fC
LDV
( 1n )1
To find the optimum cutting speed and optimum tool life for minimum
cost:
C p
V
V
=0
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Economics of machining
Solving the above equation we get
{[( ) ][
C ( Lm + Bm ) n
1 1 Tc ( Lm + Bm ) + Tg ( Lg + Bg ) + Dc
n
andd the
h optimum
i
tooll life,
lif To is
i
[( ) ]
T0 = 1 1
n
]}
Tc ( Lm + Bm ) + Tg ( Lg + Bg ) + Dc
Lm + Bm
Economics of machining
To find out the optimum tool life and optimum cutting speed for
maximum production:
Tp
V
=0
Which gives
The optimum
p
cuttingg speed
p
V0 =
{[(1n ) 1]T }
[( ) ]
T0 = 1 1 Tc
n
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
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Machinability of metals
Machinability is used to refer to the ease with which a given work
material can be machined under a given set of cutting conditions. It is
of considerable economic importance for the production engineer to
know in advance the machinability of a work material so that its
processing can be efficiently planned. The machinability of a material
is usually defined in terms of four factors:
Surface finish and integrity of the machined part,
Tool life obtained,
Force and power requirement, and
Chip control.
Because of complex nature of cutting operation, it is difficult to establish
relationships that quantitatively define the machinability of a material.
In manufacturing plants, tool life and surface finish are generally
considered to be the most important
p
factors in machinability.
y
Although not used much any more, approximate, machinability ratings
are used to get an idea about the machinability of any material.
Thus machinability is not a basic standard but is related.
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
Machinability Ratings
Specific cutting speed is defined as the cutting speed corresponding
to the predetermined tool life.
Machinability ratings can be very easily understood with the help of a
example
example.
For example if the tool life during a turning operation under standard
condition (of feed, depth of cut, tool material and tool geometry) is
found to be 60min at a cutting speed of 100 m/min, the specific
cutting speed for 60 min tool life, V60 = 100 m/min.
Further if Vt60 is the specific cutting speed for 60 min tool life for a
test material and Vs60 is the corresponding specific speed for a
standard material,
then the machinability ratings MR of the test material is given by
V60t
M R = s 100%
V60
SAE 1212 is taken as standard material for testing machinability.
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Cutting fluids
Cutting fluids, sometimes referred to as lubricants or coolants are liquids and
gases applied to the tool and work piece to assist the cutting operation.
Functions of cutting fluids:
To cool the tool.
To cool the work piece.
To lubricate and reduce friction
To improve surface finish.
To protect the finished surface from corrosion.
To wash the chips away from the tool.
Properties of cutting fluids:
High heat absorption capability.
Good lubricating quality.
High flash point so as to eliminate the hazard of fire.
Stability so as not to get oxidized in presence of air.
Neutral so as not to react chemically.
Odourless so as not to produce bad smell even when heated.
Harmless to the skin of the operators.
Non corrosive to the work or the machine.
Transparency so that the cutting action of tool may be observed by the operators.
Low viscosity to permit free flow of the liquid.
Low priced to minimize production cost.
Joyjeet Ghose, BIT, Mesra, Lecture notes on PE5005
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References
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