Merchants Circle Diagram (MCD)

Cutting Tool Materials

Cutting Fluids in machining

Forces in Machining
 Benefit of knowing and purpose of determining cutting forces

The aspects of the cutting forces concerned :

Magnitude of the cutting forces and their components
Directions and locations of action of those forces
Pattern of the forces : static and / or dynamic.

Knowing or determination of the cutting forces facilitate or are required for :

Estimation of cutting power consumption
enables selection of the power source(s) during design of the machine tools
Structural design of the machine fixture tool system
Evaluation of role of the various machining parameters ( process tool
material and geometry, environment cutting fluid) on cutting forces
Study of behaviour and machinability characterisation of the work materials
Condition monitoring of the cutting tools and machine tools.
 Forces in Machining

Fc Cutting Force
Ft Tangential Force
Ff Friction Force
N Normal Force
Fs Shear Force
Fn Normal Shear Force
 TOOL

Fc

Fc Cutting Force
Ft Tangential Force
R

These forces are measured with

Ft
the help of force sensors.
 TOOL

R
Ff Friction Force
N Normal Force
Ff

N
 TOOL
Shea
r p l an
e
Fs

Fs Shear Force
R
Fn Normal Shear Force
Fn
 TOOL
Shea
r p l an
e
Fs
Fc

Fc Cutting Force
Ft Tangential Force
R Ff Friction Force
N Normal Force
Fn
Ff Fs Shear Force
Ft
Fn Normal Shear Force

N
 TOOL
Shea
r p l an
e
Fs
Fc

Fc Cutting Force
Ft Tangential Force
R
Ff Friction Force
Fn
Ft
Ff N Normal Force
Fs Shear Force
N Fn Normal Shear Force
 Rc Cos To
tan = Where Rc = Cutting Ratio =

1 Rc Sin Tc

Ff = Ft Cos + Fc Sin

N = Fc Cos - Ft Sin

Fs = Fc Cos - Ft Sin
Fn = Fc Sin + Ft Cos
 Rc Cos To
tan = Where Rc = Cutting Ratio =

1 Rc Sin Tc

Ff = Ft Cos + Fc Sin

N = Fc Cos - Ft Sin

Fs = Fc Cos - Ft Sin
Fn = Fc Sin + Ft Cos

Coefficient of Friction
Friction angle
= Ff
N = tan ()
MERCHANTS CIRCLE DIAGRAM

(MCD)
 What is MCD?
1. Its a Graphical Ff Friction Force
method to calculate N Normal Force
Fs Shear Force
the forces in
Fn Normal Shear Force
machining

2. It is calculated from Fc Cutting Force

the measured forces Ft Tangential Force
TOOL
 TOOL

Fc
 TOOL

Fc

Ft
 TOOL

Fc

Ft
 TOOL

Fc

Ft
 TOOL

Fc

Ft
 TOOL

Fc

Ft
 TOOL

Fc

Merchants Circle

Ft
 TOOL

Fc

Ft
 TOOL

Fc

Merchants Circle

Ft
 TOOL

Fc

Merchants Circle

Ft
 TOOL

Fc

Merchants Circle

Ft
 TOOL

Fc

Merchants Circle

Ft
 TOOL

Fc

Merchants Circle

Ft
 TOOL

Fc

Merchants Circle

Ft
 TOOL

Fc

Merchants Circle

Ft
 TOOL

Fc

Merchants Circle

Ft
 TOOL

Fc

Merchants Circle

Ft
 TOOL

Fc

Merchants Circle

Ff
Ft
 TOOL

Fc

Merchants Circle

Ff
Ft

N
 TOOL

to Fc

Merchants Circle

Ff
Ft

N
 TOOL

to Fc

Merchants Circle

Ff
Ft

N
 TOOL
Shea
r Pla
ne

to Fc

Merchants Circle

Ff
Ft

N
 TOOL
Shea
r Pla
ne

Fs
to Fc

Merchants Circle

Ff
Ft

N
 TOOL
Shea
r Pla
ne

Fs
to Fc

Merchants Circle

R
Fn
Ff
Ft

N
 Theory of Metal Cutting: Force &
Power
Exercise:
During an experiment on machining, the dynamometer showed Fc to
be 1557 N and Ft = 1271 N while the workpiece was machined at a
cutting speed of 100 m/min. The rack angle is to be 10. Depth of cut
is set at 0.5 mm. After machining, the chip thickness was measured
to be 1.125 mm at w = 3 mm.
a) By graphical method of MCD, find the forces FS, F, and angles , .

40
 If the values of C and n for the basic Taylor tool-life equation are 200 and
0.25, respectively, answer the followingquestions.
A cutting speed of 50 ft/min is used. What is the tool life? The cutting
speed is increased 20 percent (to 60 ft/min). What is the effect upon tool
life?
 Shear plane angle determined by Merchant

1
=
4 2

Where
= Friction angle

= Rake angle
CUTTING TOOL MATERIALS
 CUTTING TOOL MATERIALS

1. High Carbon Steel

2. High Speed Steel (HSS)
3. Cast Alloys
4. Cemented carbides (cermet) (sintered carbide)
5. Coated Carbides
6. Ceramics
7. Diamonds
1. High Carbon Steel
This material is one of the earliest cutting materials used in machining. It is however now virtually superseded by other materials used in
engineering because it starts to temper at about 220oC . This softening process continues as the temperature rises. As a result cutting
using this material for tools is limited to speeds up to 0.15 m/s for machining mild steel with lots of coolant.

2. High Speed Steel (HSS)

This range of metals contain about 7% carbon, 4% chromium plus additions of tungsten, vanadium, molybdenum and cobalt. These
metals maintain their hardness at temperature up to about 600o, but soften rapidly at higher temperatures. These materials are suitable
for cutting mild steel at speeds up maximum rates of 0.8 m/s to 1.8 m/s.

3. Cast Alloys
These cutting tools are made of various nonferous metals in a cobalt base. They can withstand cutting temperatures of up to 760oC and
are capable of cutting speeds about 60% higher than HSS.

4. Cemented carbides (cermet) (sintered carbide)

This material usually consists of tungsten carbide or a mixture of tungsten carbide, titanium, or tantalum carbide in powder form, sintered
in a matrix of cobalt or nickel. As this material is expensive and has low rupture strength it is normally made in the form of tips which are
brazed or clamped on a steel shank. The clamped tips are generally used as throw away inserts.

5. Coated Carbides
The cutting system is based on providing a thin layer of high wear-resistant titanium carbide fused to a conventional tough grade carbide
insert, thus achieving a tool combining the wear resistance of one material with the wear resistance of another. These systems provide a
longer wear resistance and a higher cutting speed compared to conventional carbides.

6. Ceramics
Ceramics are made by powder metallurgy from aluminium oxide with additions of titanium oxide and magnesium oxide to improve cutting
properties. These have a very high hot resistance and wear resistance and can cut at very high speed. However they are brittle and have
little resistance to to shock. Their use is therefore limited to tips used for continuous high speed cutting on vibration-free machines.

7. Diamonds
Diamonds have limited application due to the high cost and the small size of the of the stones. They are used on very hard materials to
produce a fine finish and on soft materials. especially those inclined to clog other cutting materials. They are generally used at very high
cutting speed with low feed and light cuts. Due to the brittleness of the diamonds the machine has to be designed to be vibration
free. The tools last for 10 (up to 400) times longer than carbide based tools.