Metal Cutting Theory and Practice

Tafesse G b Tf Gebresenbet (PhD) b AAU, Technology Faculty, Email t f E il gstafesse@yahoo.com @ h

References: 1. 2. . 2. Shaw .M.C., Metal cutting Principles , 2nd edition Oxford clarendon Press, 2005 Boothroyd, G. and Knight. W.A, Fundamentals of Machining and Machine tools, 3rd edition, Marcel oot oy , a g t. . , u a e ta s o ac ga ac e too s, e t o , a ce Dekker, New York, 2006. Bhattacharya. - Metal Cutting Theory and Practice , New central Book Agency(p) Ltd.,Calcutta, 1984.

Methods of Machining
In the metal cutting operation, the tool is wedge-shaped and has a straight cutting edge. Basically, there are two methods of metal cutting, depending upon the arrangement of the cutting edge with respect to the direction of relative work tool motion: work-tool
Orthogonal cutting or two dimensional cutting Oblique cutting or three dimensioning cutting.

Orthogonal Machining

Oblique Machining

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Orthogonal Cutting
The Th cutting edge of the tool remains at 900 i d f h l i to the direction of feed (of the tool or the work) The chip flows in a direction normal to the cutting edge of the tool The cutting edge of the tool has zero inclination with the normal to the feed The chip flows in the plane of the tool face. Therefore, it makes no angle with the normal (in the plane of the tool face) to the cutting. The shear force acts on a smaller area, so shear force per unit area is more. The tool life is smaller than obtained in oblique cutting (for same conditions of cutting) There are only two mutually perpendicular components of cutting forces on the tool The cutting edge is bigger than the width of cut. 25/3

Oblique Cutting

The cutting edge of the tool remains inclined g g at an acute angle to the direction of feed (of the work or tool) The direction of the chip flow is not normal to the cutting edge. Rather it is at an angle to the normal to the cutting edge. The cutting edge is inclined at an angle to the normal to the feed This angle is called feed. inclination angle. The chip flows at an angle to the normal to the cutting edge. This angle is called chip flow angle. The chip flows at an angle to the normal to the cutting edge. This angle is called chip flow angle angle. The shear force acts on a larger area, hence the shear force per area is smaller The tool life is higher than obtained in orthogonal cutting There are only three mutually perpendicular components of cutting forces on the tool 25/4 The cutting edge is smaller than the width of cut.

Cutting Tool Geometry

Cutting tool is device with which a material could be cut to the desired size, shape size or finish. So a cutting tool must have at least a sharp edge. There are two types of cutting tool. The tool having only one cutting edge is called single point cutting tools. For example shaper tools, lathe tools, planer tools, etc. The tool having more than one cutting edge is called multipoint cutting tools. For example drills, milling cutters, broaches, grinding wheel honing tool etc. A single point cutting tool may be either right or left hand cut tool depending on the direction of feed.
Primary Cutting Edge

Left hand cutting tool l

Right hand cutting tool l

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Tool-inTool-in-hand Nomenclature
The geometry of a cutting tool consists of the following elements: face or rake surface, flank, cutting edges and the corner. Face or rake is the surface of the cutting tool along which the chips flow out. Flank surfaces are those facing the work piece. There are two flank surfaces, principal and auxiliary flank surfaces. Principal cutting edge performs the major portion of cutting and is formed by the intersecting line of the face with the principal flank surface. Auxiliary cutting edge surface (often called end cutting edge) is formed by the intersection of the rake surface with the auxiliary flank surface. Corner or cutting point is the meeting point of the principal cutting edge with the auxiliary cutting edge.

Tool axis Shank of tool Auxiliary cutting edge Rake or Face Principal cutting edge Principal flank surface Corner Auxiliary flank surface

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Single Point Cutting Tool

Side rake angle (x) End cutting edge angle (e)

Side clearance angle (x) Side cutting edge angle (s) Back rake angle (y)

Nose radius (r) ()

End clearance angle (y)

Note: All the rake and clearance angles are measured in normal direction

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Side Cutting Edge Angle (s): The side cutting-edge angle (SCEA) is usually referred to as the lead angle. It is the angle enclosed between the side cutting edge and the longitudinal direction of the tool The value of this angle varies between 0 tool. 0 and 90, depending upon the machinability, rigidity, and, sometimes, the shape of the workpiece. As this angle increases from 0 to 15, the power consumption during cutting decreases. However, there is a limit for increasing the SCEA, beyond which excessive vibrations take place because of the large tool-workpiece interface. On the other hand, if the angle were taken as 0, the full cutting edge would start to cut the workpiece at once, causing an initial shock. Usually, the recommended value for the lead angle should range between 15 and 30. 15 30 .

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Auxiliary or End Cutting Edge Angle (e): The end cutting-edge angle (ECEA) serves to eliminate rubbing between the end cutting edge and the machined surface of the workpiece. Al h h this angle takes values i the range hi d f f h k i Although hi l k l in h of 5 to 30, commonly recommended values are 8 to 15. Side Clearance Angle (x) and End Clearance Angle (y): Side and end clearance (relief) angles serve to eliminate rubbing between the workpiece and the side and end flank, respectively. Usually, the value of each of these angles ranges between 5 and 15.

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Back Rake Angle (y) and Side Rake Angle (X): Back and side rake angles determine the direction of flow of the chips onto the face of the tool. Rake angles can b positive, negative, or zero. I is the side rake angle that h the dominant be ii i It i h id k l h has h d i influence on cutting. Its value usually varies between 0 and 15, whereas the back rake angle is usually taken as 0. Nose radius (r): Nose radius is favorable to long tool life and good surface finish finish. A sharp point on the end of a tool is highly stressed, short lived and leaves a groove in the path of cut. There is an improvement in surface finish and permissible cutting speed as nose radius is increased from zero value. Too large a nose radius will induce chatter.

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Designation of Cutting Tools

By designation or nomenclature of a cutting tool is meant the designation of the shape of the cutting part of the tool. The following f ll i systems to d i designate the cutting tool shape which h i l h hi h are widely used are:
Tool in Hand System y Machine Reference System or American Standard Association (ASA) System Tool Reference System
Orthogonal Rake System (ORS) Normal Rake System (NRS)

Maximum Rake System (MRS) Work Reference System (WRS)

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Tool Reference System

The references from which the tool angles are specified are the
Reference plane (R) Machine longitudinal plane (x) Machine transverse plane ( y) p ( Principal cutting plane (c) Orthogonal plane (o) and Normal plane (n)

The reference plane (R) is the plane perpendicular to the cutting velocity (Vc). The machine longitudinal plane (x) is the plane perpendicular to R and taken in the direction of feed (longitudinal feed) The machine feed). transverse plane (y) is the plane perpendicular to both R and X or plane perpendicular to R and taken in the direction of cross feed. The principal cutting plane (c) is the plane perpendicular to R and containing the principal cutting edge. The orthogonal plane (o) is the plane perpendicular to R and c. The normal plane (n) is perpendicular to the p principal cutting edge. p g g

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American Standard Association System

Zm Xm
x

X X
Section B-B

Tool Character y 50 x 100 y 70 x 80 e 200 s 300 r 1/32

Y
m

A B A
e

B Xm

Y
y m

Z
m

y Y

y x y x e s r

Back rake angle Side rake angle Back or end clearance angle Side clearance angle Auxiliary or End cutting edge angle Side cutting edge angle (90o-) Nose radius (inch)

Section A-A

R
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Orthogonal Rake System (ORS)

Zo Yo C o
/

o
c/

Xo o
N X o

Zo O
0

Tool Ch T l Character t
0 70 0/ 80 e 200 300 r 0.8 mm

Section M-M

Yo
M

Section N-N

50

100

Inclination angle Orthogonal rake angle Orthogonal clearance angle l Auxiliary orthogonal clearance angle Auxiliary or End cutting edge angle Principal cutting edge angle (90-s) Nose radius (mm)

0 0 0/ e

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Interconversion Between ASA and ORS

Interrelations can be established between ASA and ORS and vice versa.Various methods are used for developing such interrelationships such as i l i hi h
Method of projection Method of slopes Method of master line Circle diagram Vector methods, etc.

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Methods of Master Line for Rake Angles

Zm Xm x T x Zm Yo Xo G C Xm
E M A/ B C B/ O

X Xo
o

D/

Zo m Xo
D M

OA=T cot OB=T OB T cot y OC=T cot o OD=T cot x OM=T cot m
T=Depth of the cutting tool

Yo Ym s

C/ F

y y Y

Zm

A
Master line H

For T=1 OA= cot OB= cot y OC= cot o OD= OD cot x OM= cot m

Setting angle for grinding rake surface m Maximum rake angle

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Prove the followings by master line methods for a single point cutting tool.
(i) t o = t x sin + t y cos tan tan i tan (ii) tan = tan x cos + tan y sin (iii) tan x = tan o sin - tan cos (iv) tan y = tan o cos + tan sin (v) tan m = tan2 o + tan2 t tan (vi) = tan tan o
1
S Setting angle f grinding rake surface l for d k f m Maximum rake angle

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tan o = tan x sin + tan y cos From Figure OBD=OBC+OCD OB.OD=OB.CE + OD.CF OB.OD=OB.OC sin + OD.OC. cos Dividing on both sides by OB.OC.OD 1 sin cos = + OC OD OB tan o = tan x sin + tan y cos tan = -tan x cos +tan y sin tan From Figure OAD = OAB +OBD A OD. AG = OB. AH + OB.OD OD. OA. sin =OB.OA COS + OB.OD Dividing on both sides by OA.OB.OD OA OB OD

Xo G Xm O E Master line

Ym F C

Yo D

B H

tan = -tan x cos +tan y sin

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sin cos 1 = + OB OD OA

OA OA= cot OB= cot y OC= cot o OD= cot x OM= cot m

Methods of Master Line for Clearance Angles

Zm Xm y T y Zm Yo Xo C Xm
O B C D M A/

X
D/

Xo
o C/ O

Zo

OA=T cot OB=T OB T tan y OC=T tan o OD=T tan x OM=T an m

T=Depth of the cutting tool

Yo Ym

Ym x
B/

Zm x Y

A
Master line

For T=1 OA= cot OB= tan y OC= tan o OD OD= tan x OM= tan m

Setting angle for grinding principal rake surface m Maximum rake angle g

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Prove the followings by master line methods for a single point cutting tool.

(i) cot o = cot x sin + cot y cos (ii) tan = cot x cos + cot y sin (iii) cot x = cot o sin - tan cos (iv) cot y = cot o cos + tan sin (v) cot m = cot2o + tan2 tan t o (vi) = tan cot
1
Setting angle for grinding principal rake surface m Maximum rake angle

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cot o = cot x sin + cot y cos From Figure OBD=OBC+OCD OB.OD=OB.CE + OD.CF OB.OD=OB.OC sin + OD.OC. cos Dividing on both sides by OB.OC.OD 1 sin cos = + OC OD OB cot o = cot x sin + cot y cos tan = -cot x cos +cot y sin cot From Figure OAD = OAB +OBD OD. AG = OB. AH + OB.OD OD. OA. sin =OB.OA COS + OB.OD Dividing on both sides by OA.OB.OD OA OB OD

Ym Xo Xm G O E B H

Yo F M C D

Master line

tan = -cot x cos +cot y sin

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sin cos 1 = + OB OD OA

For T=1 OA= cot OB= tan y OC= tan o OD= tan x OM= tan m