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 Metal cutting
‡ It is the process of producing work piece by removing
unwanted material from a block of metal, in the form of
chips.
 ÄINGLE POINT CUTTING TOOL
Ähank. It is main body of tool
Flank. The surface below &
adjacent to cutting edge is
called flank of the tool.
Face. The surface on which
the chip slides is called is
called face of the tool.
Heel. It is the intersection of
flank & base of the tool.
Nose. It is the point where the side cutting edge & the end
cutting edge intersect.
Cutting edge. It is the edge on the face of tool which removes
material from work piece.
Types of surfaces
Three types of surfaces:
1.The work surface

2.The machined surface

3.Cuttting surface
 esignation of cutting Tools
It means the designation of the shape of the part of cutting
tool. Two system to designate the tool shape are:
1.American Ätandards Association Äystem (AÄA)
2.Orthogonal rake system (ORÄ)
'    In this
  
system, angles of the tool
face, are defined in two
orthogonal planes, one
parallel to & the other
perpendicular to, axis of the
cutting tool, both planes
being perpendicular to the
base of the tool.
 sarious tool angles
Ä
 
 
Ä Ö
Cs, also known as lead angle,
is angle between the side cutting
edge & the side of the tool shank.
The complementary angle of
ÄCEA is called ³Approach angle´.

 
 
  
It is the angle between the end
cutting edge & a line normal to the
tool shank.
Ä

 
Ä
It is angle between the portion of
the side flank immediately below
the side cutting edge & a line
perpendicular to the base of the
tool.
 


 
  It is the angle between the portion
of the end flank immediately below the end cutting edge & a
line perpendicular to the base of the tool & measured at
right angle to the end flank.
Î   
BR)Įb It is the angle between the face of
the tool & a line parallel to the base of the tool & measured
in a plane through the side cutting edge. This angle gives
the slope of the face of the tool from the nose towards the
shank.
Ä
  
ÄĮOit is the angle between the tool
face & a line parallel to the base of the tool & measured in a
plane perpendicular to base & the side cutting edge. This
angle gives the slope of the face of the tool from the cutting
edge
V÷


it is favorable to long tool life & good
surface finish. The use of following values for nose
radius is recommended:
R=0.4 mm, for delicate components
> 1.5mm for heavy depth of cut
=0.4 to 1.2 mm for disposable carbide
inserts
=1.2 to 1.6 mm for heavy duty inserts

c

  it is given in the order given as
BRA, ÄRA, ERA,ÄRA, ECEA, ÄCEA, Nose radius
that is
Įb ±Įs ±șe ±șs ±Ce -Cs -R
 Orthogonal rake system (ORÄ)
In this system the planes for designating tools are the planes
Containing the principal or side cutting edge & the plane
normal to it. Plane NN is known as orthogonal plane. we have
following angles:
Ä

`


  

  


O
 

Back rake, side rake, O 
 end relief, end
cutting edge angle,
approach angle, nose
radius
    


 Methods of machining
Two methods of metal cutting,
1.Orthogonal cutting or 2 cutting
2.Oblique cutting or 3 cutting

O O
   O

The cutting tool is completely defined by rake angle Į & the
clearance angle Ȗ & following assumptions are made
1.The tool is perfectly sharp.
2.The primary deformation takes place in a very thin zone
adjacent to the shear plane AB,
3.There is no side flow of the chip.
Ähear angle Ø, is defined as angle made by the shear
plane, with the direction of tool travel.
t= uncut chip thickness
tc= chip thickness after metal is cut
r=t/tc is called the cutting ratio
ç =1/r is called the chip reduction factor
 
O
! !" 
"O
#$ 
ØØ =rcosĮ
=rcosĮ/1
/1--r sin
sinĮ
Į

(b) If length of cut is l & length of chip is lc, then

r=lc/l =t/tc
after putting r in above equation, we can get Ø.
(c) If length of cut is not known, then by weighing a known
length of chip.
Wc=plbt ,therefore l=Wc/pbt
(d) If chip & work piece velocities sc & s are known
r=t/tc=sc/s
 Cont«
The shearing process in metal cutting can be represented
by a simple model
shear strain can be given as

s=distance sheared/thickness of zone

=AB/OC

=Cot Ø+ tan(Ø-
tan(Ø-Į)
 selocities
Three kinds of velocities are involved in metal cutting :
1.The velocity of tool relative to work piece, s is called
cutting speed
2.The velocity of the chip relative to the work, ss is called
shear velocity.
3.The velocity of the chip up the face of tool, sc is called
chip velocity.
r= sc/v=t/tc
From the figure
ss/s=Cos
ss/s=CosĮ Į/cos(Ø
/cos(Ø--Į)
sc/s=sinØ/cos(Ø--Į)
sc/s=sinØ/cos(Ø




max. value of ts =.025mm
etermination of under formed chip thickness
From the figure
t=fsinȜȜ & b=d/sinȜ
t=fsin b=d/sinȜ
for drilling operation, tool has
2 cutting edges, thus
t=f/2*sinȜȜ
t=f/2*sin

In fig (c) where Ȝ=90deg.

& Ce is not 0
t=f & b=d
& width of cut=depth of cut
Äuch a case is called
³Restricted Orthogonal cutting´
 Force relations
When a cut is made, the forces acting on the chip are:
1.Force Fs, which is resistance to the shear of the metal
forming the chip. it acts along the shear plane.
2.Force Fn normal to the shear plane.
3.Force N at the tool chip interface acting normal to the
cutting face of the tool& is provided by the tool.
4.Force F is the frictional resistance of the tool acting on
the chip. It acts downward against the motion of the chip
as it glides upward along the tool face.
It is easily shown that

F=Fc sinĮ
sinĮ+Ft cos
cosĮĮ
N=Fc cosĮ
cosĮ-Ft sin
sinĮ
Į
 Cont«
ȗs=
s=Fcsec(
Fcsec(ȕ
ȕ-Į).cos(Ø+
).cos(Ø+ȕȕ-
Į).sinØ
bt
Max. shear stress,
į ȗs = 0
įØ
Therefore Ø=45deg.+Į
Ø=45deg.+Į/2
/2--ȕ/2
For practical purposes Ø has been
suggested
Ø=Į,
Ø=Į for Į>15 deg
Ø=15 deg. for Į <15 deg.
 %
 O   
O 
 & 
! 
  


U

 #ȕĮ$
U
Cutting power
 O 
O'% 
(
E=Fc*s
Power assumed in cutting ,Pc=Fc*s kw
60*102
s=UN/60*1000 m/s
Fc=C dxf ys n
The values for constants are
C=300, x=1,y=.75, n=-0.15
A) hot rolled 0.2% C-
C-steel
Fc=162.4f 0.85 d 0.98kgf
b) 18 -8 stainless steel
Fc=196.7 f .85 d .96 kgf
c) Yellow brass
Fc=123.6 f 0.81 d .96 kgf
constant C is given as
=60.2 for BHN 126
=111.6 for BHN 181
=131.1 for BHN 241
d & f are in mm.
Power needed to make particular cut:
power=dfsC, watts

For negative rake cutting, increase value of C by 50%.

?
 
 

it is expressed as mm3/min.
for a single point tool, MMR
= Ac s
Ac
 Ac =cross sectional area of uncut chip
 b* t
 Energy consideration in metal cutting
Total energy consists of two main parts:
shear energy, Es
friction energy, Ef
E=Es+Ef
The energy per unit time divided by volume removed
Per unit time, is known as specific energy.
Total specific energy, e=E/bts=Fc/bt N/mm2
Äpecific shear energy, e s=Es/bts=Fsss/bts
Äpecific friction energy, ef=Ef/bts =Fsc/bts
Now ss/s=Cos
ss/s=CosĮ Į/Cos(Ø
/Cos(Ø--Į)
sc/s=t/tc=r
put values of ss/s & sc/s in e value & get the result.
 Oblique cutting
nc is chip flow angle
Įn=normal rake angle
Įe=effective rake angle
i=0, Įn will be equal to Į
From the geometry
sin Įe=sin2i+cos2isin Įn
 Tool wear & tool life
Tool wear may be classified as
a) Flank wear
b) Crater wear on tool face
c) Chipping off cutting edge
d) Localized wear
c


The total cutting time accumulated before tool failure occurs is
termed as tool life. The most commonly used criteria for
measuring the tool life are:
1.Total destruction of tool when it ceases to cut
2.A fixed size of wear land on the tool flank. Tool life is taken
as 0.038 or 0.076mm wear land on the flank for finishing.
Taylor formula between cutting speed & tool life,
sT n=C
s is cutting speed, T is time for the flank wear to
reach a certain dimension, C is constant & n is
exponent depends upon the cutting conditions.

n=0.1 to 0.15 for HÄÄ tools

=0.2 to 0.4 for carbide tools
=0.4 to 0.6 for ceramic tools
 Economics of metal cutting
Total cost of cutting a unit volume of metal=cost of
machining metal per unit volume of metal cut+ cost
of replacing tools per unit volume of metal cut.
let Cm=machining cost per minute
Ct =tooling cost
Optimum total cost,
s=C {Cm*n/Ct(1-
{Cm*n/Ct(1-n)}n

s0=C/{Tc(1
=C/{Tc(1--n/n)}n

T0=Tc(1
=Tc(1--n/n)
 Machineability
' The ease with which it could be machined
2.The life of tool before tool failure
3.The quality of the machined surface
4.The power consumption per unit volume of material
removed.
Machineability index,%
=cutting speed of material for 20 min tool life *100
cutting speed of free cutting steel for 20 min tool life
Machineability index for common materials

C- steel =65 copper = 70

C- 45 steel =60 brass =180
stainless steel =25 Al alloys=300-
alloys=300-1500
 Äurface roughness
The quality of the surface produced during machining
process will depend upon:
1. Tool geometry & feed rate
2. Irregularities in machining process
Irregularities include:
1.Occurance of B.H.U
2.Occurrence of vibration & chatter
3.eflection of the tool or workpiece
4.Inaccuracies in movements of spindles , slides & feed
mechanism of machine tool
5.Formation of discontinuous chip when cutting brittle
materials
6. Flow of chips on machined surface
 Ideal surface roughness
The surface roughness produced will depend entirely
on tool geometry such a surface roughness is
called ideal surface roughness.

sum of all area above &

Ra= below the mean line
sampling length

Two areas are equal

Ra=2/f(area 1)=h/4
where h is height of
Geometry of the surface
roughness
h=f2/8R Therefore,
Ra=f2/18
/18¥3.R
¥3.R
 Natural surface roughness
Äurface roughness obtained will depend upon the
combined effect of tool geometry & the contributing
factors , such a surface roughness is called natural
surface roughness.