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Px
Py
Pz
18/2
Px
Pxy
Pz
Py
Pz
18/3
R
XY
Z
Pz
Pxy
X
Pxy
Py
Px
18/4
Pn
R2
Chip
Ps Pxy
F
R
R1
Workpiece
Department of Industrial & Production Engineering
Pz
Tool
18/5
R = F + N = P + P = P + P .......[3]
s n
z
xy
F = Pz sin o + Pxy cos o .....................[4]
Pxy
Pn
R
Pz
-o
Ps
Chip
o
Tool
Workpiece
18/6
Pz = R cos( 0 )................[9]
Ps = R cos( + 0 )...........[10]
Fron Equation [9] and [10]
cos ( 0 )
Pz = Ps
..........[11]
cos ( + o )
Based on the shear force, the shear stress
(s) which acts along the shear plane
between the work and the chip is:
Pxy
R
F
s =
Ps
S t
, where As = area of the shear plane = o
As
sin
s =
Ps sin
..........[12]
So t
Pn
Pz
-o
Ps
Chip
o
Tool
Workpiece
18/7
cos( 0 )
Pz = s S0 t
...........[13]
sin cos( + o )
Similarly,
sin( 0 )
Pxy = s S0 t
.......[14]
sin cos( + o )
Pxy
Pn
R
Pz
-o
Ps
o
In metal cutting one of the main problem is to
evaluate the cutting forces Pz and Pxy from the
given cutting conditions and initial properties of
work material and it is necessary to determine s,
and by suitable relationships.
Chip
o
Tool
Workpiece
18/8
Earnest-Merchant Theory
Ernst and Merchant extended their analysis and studied the relationship between the shear
angle and the cutting conditions. They suggested that the shear angle always takes the value
that reduces the total energy consumed in cutting to a minimum. Because the total work done
in cutting is dependent upon and is a direct function of the component Pz of the cutting force,
they developed an expression for Pz in terms of and the constant properties of the workpiece
material. Condition for maximum cutting force (Pz) from Equation [13]
dPz
dP
d s S0 t
cos( 0 )
= 0, or, z =
.
=0
d
d d sin cos( + o )
18/9
Merchant Theory
Merchant modified the relationship derived by Earnest-Merchant, by
assuming that the shear stress along the shear plane varies linearly with
normal stress (n). It is given as (from the following Figure).
= + k ................[17]
s
0
n
From the geometry of force relations of MCD
P = R cos( + ) and P = Rsin( + ) ................[18]
s
0
n
0
s
P = P tan( + )
n
s
0
P
P
n = s tan( + )
0
A
A
s
s
= tan( + ) ....................[19]
n
s
0
From Eqation [17] and [19]
0
=
.......................[20]
s 1 k tan( + )
0
0
n
18/10
or
=0
2
[ sin cos( + 0 ) k sin sin( + 0 )]
cos(2 + ) k sin(2 + ) = 0
0
0
cot(2 + ) = k
0
2 + = cot 1(k) = c 800 to 850...........................[22]
0
From Equation [21] and [22]
P = S t[ cot + tan(c ) ]..........[ 23]
z
s 0
Department of Industrial & Production Engineering
18/11
The material ahead of the cutting tool behaved as ideal plastic material
The chip does not get hardened
The chip and parent work material are separated by a shear plane.
+ 0 = ......................[24]
4
From Equation [13] and [24]
Pz = s S0 t ( cot + 1)..............[25]
Where,
cot =
1
sin o
=
tan o
tan
cos o
Pz = s S0 t ( tan 0 + 1)............[25]
18/12
adversely affect the strength, hardness and wear resistance of the cutting
tool
cause dimensional changes in the part being machined, making control of
dimensional accuracy difficult and
can induce thermal damage to the machined surface, adversely affecting its
properties and service life.
18/13
q1
q3
Workpiece
Chip
q2
Tool
=
cutting
tool
+
Amount
of
heat
passing
into
the
workpiece
+
Amount
of heat generated
18/14
0.4 U Vc t
T=
C K
0..333
where,
T = mean temperature rise at the tool-chip interface (oC)
U = specific energy in the operation (N-m/mm3)
Vc = cutting velocity (m/sec)
t = depth of cut (mm)
pC = volumetric specific heat of the workpiece (J/mm2-C)
K = thermal diffusivity (ratio of thermal conductivity to volumetric specific heat) of the
workpiece material (m2/sec).
18/15
Exercise
The dynamometer recorded the following, feed force 200 kg, cutting force
300 kg. The rake angle of the tool used was 10o. The chip thickness ratio
0.35. Find
Shear angle ()
Shear force (Ps)
Co-efficient of friction at the chip-tool interface () and the friction angle ()
Compressive force at the shear plane (Pn).
Co-efficient of friction
Chip thickness ratio
Shear plane angle
Velocity of the chip along the tool face
Velocity of shear along the shear plane
18/16
18/17
Any questions or
comments?
18/18