Mechanics of Cutting

Geometry of chip Formation:

tc : Chip thickness
tu : Uncut chip thickness
V f : Chip Sliding Velocity
Vs : Shear Velocity
Vc : Cutting Velocity
: Shear Angle
ABC & ABD
t
AB = u
sin
tc tc
also, AB =
sin(90 ( )) cos( )
tu sin
90-+ = 90-(-)
=
tc cos( ) Fig: Schematic of Geometry of chip formation
SHEAR ANGLE AND CHIP THICKNESS RATIO EVALUATION
tu
rc = : Chip thickness Ratio / Coeffinicient Substitute the value of tu /tc
tc
from earlier slide and simplify to get:
1 cos cos + sin sin
=
rc sin
1 rc cot cos + rc sin
rc cos= (1 rc sin ) tan

rc cos
tan =
90-+
1 rc sin = 90-(-)

How to determine & rc ?

tc should be determined from the chip. tu (= feed) and are already
known.
To determine tc with micrometer, is difficult and not so because of
uneven surface. How? (say, f=0.2 mm/rev. An error of even 0.05 mm will cause
an error of 25 % in the measurement of tc)
Volume Constancy Condition: Volume
Dr. V.K.jain, of Uncut chip = Volume of cut chip
IIT Kanpur 3
SHEAR ANGLE AND CHIP THICKNESS RATIO EVALUATION

Lu tu b = Lc tc b Lc = Chip length
Lc tc =
Lu tu L u = Uncut chip length
b = Chip width
tu Lc
or , r=
c = (2-D Cutting)
tc Lu
LENGTH OF THE CHIP MAY BE MANY CENTIMETERS HENCE THE ERROR IN EVALUTION OF
rc WILL BE COMPARATIVELY MUCH LOWER.

(rc = Lc / Lu)

Dr. V.K.jain, IIT Kanpur 4

 FORCE CIRCLE DIAGRAM

Chip
G Tool
Fs
F E Fc Clearance Angle
A

B Work
Ft
Fn
R

F FAD = ( - )
GAD = + ( - )

D N

79
 Force Analysis
Forces in Orthogonal Cutting:
Friction force, F
Force normal to Friction force, N G
Cutting Force, FC
F
Thrust force, Ft A
Shear Force, FS
Force Normal to shear force, Fn
Resultant force, R

C
Force Circle Diagram

FREE BODY DIAGRAM

R =' F + N

R = F S + F N = F c + Ft = R '
Dr. V.K.jain, IIT Kanpur 6
 Force Analysis

=F Ft cos + Fc sin

=N Fc cos Ft sin

Coefficient of Friction ( )

F Ft cos + Fc sin
tan
= = =
N Fc cos Ft sin

= Friction Angle DIVIDE R.H.S. BY Cos

Ft + Fc tan
= also, = tan 1 ( )
Fc Ft tan
Dr. V.K.jain, IIT Kanpur 7
 Foce Analysis

=FS Fc cos Ft sin

=FN Ft cos + Fc sin

also,

=FC R cos ( ) FAD = ( - )

GAD = + ( - )
FS R cos ( + )
=

FC cos ( )
=
FS cos ( + )

t u b tu
ShearPlaneArea (=
AS ) = b
sin sin
Dr. V.K.jain, IIT Kanpur 8
 Foce Analysis
Let be the strength of work material
tu b
= S
FS A=
sin

t b cos ( ) t b
1
FC = u and =
, R u
sin cos ( + ) sin cos ( + )

tu b sin( )
Ft = R sin( )=
sin cos ( + )

Ft
= tan( )
Fc
Dr. V.K.jain, IIT Kanpur 9
 Foce Analysis

FS
Mean Shear Stress (tchip ) =
AS
(On Chip )
( Fc cos Ft sin ) sin
=
b tu

FN
Mean Normal Stress ( chip ) =
AS
(On Chip )

( Ft cos + Fc sin ) sin

=
b tu

Dr. V.K.jain, IIT Kanpur 10

 VELOCITY ANALYSIS

Vc : Cutting velocity of tool relative to workpiece

V f : Chip flow velocity

Vs : Shear velocity

Using sine Rule:

Vc Vf Vs
= =
sin(90 ( )) sin sin(90 )

Vc Vf Vs Vc sin
= = and V = = Vc rc
cos( ) sin cos cos( )
f

Vc cos V cos
=Vs =
s 11
cos( ) Vc cos( )
 Shear Strain & Strain Rate

Two approaches of analysis:

Thin Plane Model:- Merchant, PiisPanen, Kobayashi & Thomson

Thick Deformation Region:- Palmer, (At very low speeds) Oxley, kushina,
Hitoni

Thin Zone Model: Merchant

ASSUMPTIONS:-
Tool tip is sharp, No Rubbing, No Ploughing
2-D deformation.
Stress on shear plane is uniformly distributed.
Resultant force R on chip applied at shear plane is equal, opposite and
collinear to force R applied to the chip at tool-chip interface. 12
 Expression for Shear Strain
The deformation can be idealized as a process of block slip (or preferred
slip planes)

deformation
ShearStrain( ) =
Length

s AB AD DB
= =
= + = tan( ) + cot
y CD CD CD

sin( ) sin + cos cos( ) cos

=
sin cos( )
, sin cos( )
Dr. V.K.jain, IIT Kanpur 13
 Expression for Shear Strain rate
In terms of shear velocity (V s ) and chip velocity (Vf), it can be written as

Vs Vs cos
= since
Vc sin Vc cos( )

Shear strain rate ( )
s

d y s 1
=
= =
dt dt y y
Vs Vc cos
= =
y cos( )y

where, y : Mean thickness of PSDZ

Dr. V.K.jain, IIT Kanpur 14
 Shear angle relationship
Helpful to predict position of shear plane (angle )

Relationship between-
Shear Plane Angle ()
Rake Angle ()
Friction Angle()

Several Theories
Earnst-Merchant(Minimum Energy Criterion):
Shear plane is located where least energy is required for shear.

Assumptions:-
Orthogonal Cutting.
Shear strength of Metal along shear plane is not affected by
Normal stress.
Continuous chip without BUE.
Neglect energy of chip separation. Dr. V.K.jain, IIT Kanpur 15
 Shear angle relationship
Assuming No Strain hardening:
dFc
Condition for minimum energy, =0
d
dFc cos cos( + ) sin sin( + )
tu b cos ( )
d sin cos ( + )
2 2

=0

cos cos( + ) sin sin( + ) =

0
cos(2 + ) =
0

2 + =
2
1
= ( )
4 2
Dr. V.K.jain, IIT Kanpur 16
THANK YOU

Dr. V.K.jain, IIT Kanpur 17