6/5/2017 Cutting force By Mesay Alemu,Jimma,Ethiopia 1

General method of cutting force measured.

Analytical and Experimental
Using Numerical (calculation)
Easy quick and inexpensive, very approximate,
average and Unable to reveal dynamic aspect
Dynamometers device(cutting force Dynamometers)

Accurate , can depict both static and dynamic and

its expensive

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017

 Cutting force components and their significances
3

Cutting force R resolved into PX, PY and PZ Turning force resolved into PZ, PX and PY

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017

 Significance of PZ, PX and PY
4

PZ : called the main or major component as it is the largest in

magnitude. It is also called power component as it being acting
along and being multiplied by VC decides cutting power
(PZ.VC) consumption.
Py : may not be that large in magnitude but is responsible for
causing dimensional inaccuracy and vibration.
PX : It, even if larger than PY, is least harmful and hence least
significant.

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017

 The cutting force tool video\dislocation
density simulation in cutting of titanium
5 using Abaqus.avi - YouTube.FLV
Externally applied forces tool video\Orthogonal Cutting_ ALE App
P

Fc

Fc Cutting force, Ft Thrust force Ft

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017

 The cutting force
6

Forces on the tool

Fn

F Friction force, Fn Normal force

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017

 The cutting force
7

Forces on the chip

Fs

Fco

Fs Shear force, Fco Compressive force

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017

 The cutting force
8
Merchants theory

= + ( )
1
4 2

Fs

Fco -
Ft
R
F
- F
c
friction angle
Fn
Merchants Circle
Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017
 Cutting force cont.
9

[
R = Fc + Ft
2 2
]1
2

R = [F ]
1

+ Fn
2 2 2
f

R = [F ]
1

+ Fco
2 2 2
s

The shear force Fs To shear a work material can be expressed in terms of

cutting force F
c
Fs = Fc cos Ft sin

Area of shear As is given by

Ac
As =
force By Mesay Alemu,Jimma,Ethiopia
sinCutting 6/5/2017
 The cutting force cont.
The shear strength of a material s on the shear plane
may be obtained by
10

Fs ( F cos Ft sin ) sin

s = = c
As Ac
Ernest and merchant theory suggests that is formed in such a
way that the energy required to shear a material wil
Fs

Fco
+ s Shear strength

R As Area of shear

AC Area of uncut chip

Fs = FR cos( + )
Cutting
s Acforce By Mesay Alemu,Jimma,Ethiopia
Fs = s As = 6/5/2017
sin
 The cutting force cont.
11

s Ac
1
FR = cos( + )
sin

FC = FR cos( )

s Ac cos( )
Fc = cos( + )
sin
The equation my now be differentiated with respect to equal
to zero to find the value of for which F c is minimum.
dFc
=0
d

Solution = 4 + 1 2 ( )
Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017
 The cutting force cont.
12

The result didnt agree with the experimental , since the assumption
Didnt considered the dependency of shear stress with shear angle
Merchant reconsidered the assumption and he included his new
Assumption

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017

 The cutting force cont.
13

Fco = FR sin( + ) Fs
s Ac
Fco = s As =
sin +
sin Fco
s = ( FR sin( + ))
Ac R
s
cot( + ) =
s
s = s cot( + )
s
s = so +k
cot( + )
so
s =
Cuttingforce
1 k tan( + By Mesay
Alemu,Jimma,Ethiopia
) 6/5/2017
 The cutting force cont.
14

s = f ( , , )
The new equation for Fc
Ac so cos( )
FC =
sin cos( + )(1 k tan( + ))

It is now assumed that K and so are constants for a particular

Material
Ac and are constants for the cutting operation
dFc
=0
d
= 1
2 (c + ) c Is constant
Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017
 Lee and Shafers solution
15

The theory of lee and Shafer's was the result of an

attempt to apply the plasticity and slip lines theory
to orthogonal metal cutting
Assumptions
The material is rigid
The behavior of the material is independent of the rate of
deformation
The effect of temperature during deformation is neglected

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017

 Lee and Shafers solution
16

ABC is deformation zone

AB shear plane
AC is stress free so that slip lines
meet this line at an angle of 45
Slip lines :
Parallel to AB
Perpendicular to AB

= 4 + ( )

The theory of lee and Shafer's is not applied for tools with
negative rake angle .
Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017
 Influence of cutting parameters on
17
cutting force

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017

 Friction force
18

Fig Sliding friction Fig Sticking friction

Ar Aa Apparent area
Real area

Fn
Ar = F f = f Ar
y f Shear strength

Ff Ff Friction force
=
Fn Fn Normal force

Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017

 Cutting forces on turning
19

Fc Cutting force
Ff Feed force
Thrust force

No motion on the radial

No work done by radial motion
The feed force is negligible
Power(P) needed for turning is :
FcVc [Watt ]
P=
60Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017
 Specific cutting Energy
20

The rate of energy consumption during machining Pm is

Pm = FcV
The energy consumed per unit volume of metal removed
,specific cutting energy Ps is
Pm Fc
Ps = =
Z w Ac
Pm Power consumed
Fc Cutting force
Ps Specific cutting energy
Z w Metal removal rate
Ac Un deformed chip cross section
Cutting force By Mesay Alemu,Jimma,Ethiopia 6/5/2017