Forces and Mechanics of Cutting

Why should we know?

Power requirement for the machine tool can be calculated Design of stiffness, etc. for the machine tolerances Whether workpiece can withstand the cutting force

 Ernst and Merchant (1941) did the first scientific analysis

Normal = N Along the tool = F
F = N

FC and FT along and normal to cutting along the direction of tool movement with velocity, v.
FC = FS cos + FN sin FT = FN cos FS sin
(1) (2)

F = FC sin + FT cos N = FC cos FT sin FS = FC cos FT sin FN = FC sin + FT cos FS R= cos( + ) FC = R cos( ) FT = R sin ( )

(3) (4) (5) (6) (7) (8) (9)

 We can measure FC and FT using force dynamometer. FS, FN, F, and N can be found.
FS and FN from equations 5 & 6. F and N from 3 & 4
F = = tan N
=

= friction angle)
Eq. 10

FC sin + FT cos FC cos FT sin

 Cutting Force FC depends on

FC increases as t0 increases FC decreases as rake angle increases and as speed increases

Why FC is affected by speed:

As speed goes up, shear angle goes up, and friction reduces.

Forces can also be affected by the nose radius. Large nose radius increases force. (Blunt tool)

 Large nose radius can create positive rake angle and cause rubbing and create plastic deformation.

 Coefficient of friction in metal cutting range from 0.5 to 2.0 Shows how high friction can rise on the chip-tool interface Forces on the tool tip are very high because of small contact area.

Stresses
Average shear stress Average normal stress
FS = AS
FN = AS

The area where the stress acts (area of shear plane)

wt0 AS = sin

AS can be increased by increasing t0. is independent of rake angle decreases with increase in rake angle.

 Consequently, normal stress in the shear plane has no effect on the magnitude of shear stress. Problems in finding stresses on the rake face:
Hard to find the contact on the rake face. Stresses in practice is not uniformly distributed on the rake face.

Shear-angle relationship
Lets take friction angle as FC = R cos( ) FS = R cos( + )

In the previous slides we called this

wt 0 AS = sin ( ) FS FC sec( ) cos( + ) sin = = AS t 0

Assume is independent of . Differentiate with respect to and equate to 0 (zero).

tan ( + ) = cot = tan ( 90 ) o (A) = 45 + 2 2

The equation (A) shows that If decreases and/or increases then decreases. In practice this analysis is corrupted because of several reasons like:
Shear stress is effected by normal stresses. is effected by etc. (see graph 8.19)

Specific Energy
Total power = FCV If width of unit = W Total energy/unit volume of material removal. Frictional specific energy: FVC Fr r ( FC sin + Ft cos ) u = = =
f

FCV FC ut = = t0V t0

t0V

t0

t0

 Power required to shear along the plane

FSVS us = t0V ut = u f + u s

As uf increases, shear angle decreases, and hence us goes up directly. Thus friction plays an important part in metal cutting.
uf sin sin = ut cos( ) cos( )

 t0=0.005 in, V=400 ft/min, =10o, =0.25, tc=0.009, Fc=125 lb, Ft=50 lb. What % of total energy is consumed in friction?

Problem

Summary
Velocity triangle Merchants circle Compute Forces and obtain Fs, Fn etc based on measuring Fc and Ft (Equations 1 to 10 of this slide set) Calculate Shear stress and normal Stress Specific energy Shear angle relationships Relationships between rake angle, velocity, shear angle and cutting force Effect on Ft due to ve and +ve rake angle.