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Fig. 19.4 (a) Single-point tool showing rake face, flank, and tool point; (b) a helical
milling cutter, representative of tools with multiple cutting edges
Fig. 19.2 Cutting action involves shear deformation of work material to form a chip, and as
chip is removed, new surface is exposed: (a) positive and (b) negative rake tools
Cutting Conditions
- Cutting speed v [m/min] the primary motion direction, the velocity of the cutting
tools relative to the workpiece.
- Depth of cut d [mm] the distance for cutter projects below the original surface.
- Feed f [mm/rev], for turning or [mm/tooth] for milling relative lateral movement btw
tool and workpiece.
2
- Feedrate F [mm/min] for both turning and milling time derivative of the feed, the
velocity of the tool lateral motion.
- Spindle speed N [rpm ]=[rev/min] part rotating speed (for turning) or tool rotating
speed (for milling).
3
- Material Removal Rate (RMR) mm - removed the workpiece volume per unit
min
time.
Rough Cut remove large amount of materials as rapidly as possible, and leave
some materials (called stock) on the workpiece for subsequent finish cut. Rough cut
uses large MRR, f = 0.4~1.25 mm/rev, d = 2.5~20 mm
Finish Cut achieve the final dimension, tolerance, and surface finish; f around
0.125~0.4 mm/rev, d =0.7 2 mm.
ls
Fig. 19.6 Orthogonal cutting: (a) as a three-dimensional process, and (b) how it reduces to
two dimensions in the side view (Fig. 19.13)
- = Shear angle l s Shear plane; = Rake angle; to = Chip thickness before chip
formation; to area is the material to be removed; tc = Chip thickness after chip formation;
Chip thickness ratio r = to
1
tc
3
Ex 19.1 (P.481)
Actual chip formation
Fig. 19.8 More realistic view of chip formation, showing shear zone rather than shear
plane. Also shown is the secondary shear zone resulting from tool-chip friction
Two shear zones of chip formation
Primary shear zone the primary shear action area, in reality, the shear
deformation occurs within a thin shear zone, rather than a plane of zero thickness.
Since this zone in only a few thousands of an inch, it can be modeled as a plane
Secondary shear zone due to the friction contact btw chips and the tool
Enable to select a machine tool with proper powers (from users view point)
Enable to design the machine stiff enough to withstand the high cutting force
presented during cutting, which may cause excessive distortion and furthermore
leads to inaccurate machining (from machine designers view point).
Cutting forces can be measured by a force dynamometer.
Fig. 19.13
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(1) Cutting force Fc - It is the primary cutting force, which is the largest force
(accounts for largest power required).
(2) Feed force Ff (or called thrust force Ft ) - Acts in the feedrate direction.
It accounts for very small percentage of power required since feedrate is usually very
small compared to the cutting speed v.
(3) Radial force Fr - The smallest force involves during cutting, which can be
neglected.
Force relationship
Fig. 19.10 Forces in metal cutting: (a) forces acting on the chip in orthogonal cutting (b)
forces acting on the tool that can be measured
Secondary shear zone (due to the friction btw chips and tools)
Friction force (F) = N,
Normal force (N) to friction
Moving direction
F
N
F N
= the friction coefficient = tan , = friction angle, the angle btw F and N = the
min angle that makes the mass slide down automatically.
6
E
C
D F
A
7
G A
D
(19.13)
(19.14)
(19.13)
(19.14)
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Merchant Equation
How large the shear angle will be, to get the best performance?
vf
10
11
Figure. Typical distribution of total cutting energy among the tool, work, and
chip as a fun. of cutting speed (supplement)
(20.1)
(20.2)
(20.3)
(20.4)
RMR
(20.6)
Peripheral milling
Figure 20.18 Peripheral milling: (a) slab milling, (b) slotting, (c) side
milling, (d) straddle milling, and (e) form milling.
Peripheral milling can be separated into (a) up milling and (b)
down milling (Figure 20.19)
(1) Up milling (or called conventional milling)
Cutting speed direction is opposite to the feed direction.
Pull up the part
Chip from thin to thick
(2) Down milling (or called climb milling)
Cutting speed direction is the same as feed direction
Hold down the part
Chip from thick to thin
Longer tool life due to the chip length is shorter
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Face milling
Figure 20.20 Face milling: (a) conventional face milling, (b) partial face
milling, (c) end milling, (d) profile milling, (e) pocket milling, and (f)
surface contouring.
Cutting Conditions in Milling
(20.13)
(20.14)
Fig. 20.21
(20.17)
(20.16)
(20.15)
Fig. 20.22
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(20.19)
(20.20)
Machining processes
An accurate process in terms of dimension accuracy and surface
finish.
Milling machines: Figure 20.23 to 28
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Tool wears
Crater wear on top of the rake face due to the chip sliding against the rake face.
Flank wear on the flank face due to contact btw the flank face and the newly
generated part surface.
Figure 21.1 Types of wear
Fig. 21.2 (a) Crater wear and (b) flank wear
Figure 21.3 Tool (flank) wear as a function of time. Crater wear follows a similar
growth curve
Figure 21.4 Effect of cutting speed on tool flank wear for three cutting speeds for a tool
life criterion of 0.5mm (0.02 in)
The tool life is defined as the cutting time that the cutter can be used before fracture.
But in practical uses, the tool is replaced before it breaks. This is because
(1) the breaking may damage the part or is difficult to recover from the middle
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process;
(2) the tool wear is rapidly near fracture that results in producing unqualified
parts.
- Taylor plotted the relationship btw the cutting speed and tool life in log-log
scale. It became a linear relationship.
Figure 21.4 Effect of cutting speed on tool flank wear for 3 cutting speeds.
Figure 21.5 Natural log-log plot of cutting speed vs. tool life (correction for 4th version)
Table 21.2
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Tool Materials
Tool failures are due to the high cutting temp and cutting force. Therefore, good
cutting tool materials have the following properties:
(1) Good toughness
(2) Good hot hardness .
(3) Good wear resistance
Fig. 21.8 Two methods of chip breaking: (a) groove-type and (b) obstruction-type chip
breakers
Figure 21. 9 three ways of holding the cutting edge for a single point tool: (a) solid tool,
(b) brazed insert, and (c) mechanical clamped insert for cemented carbides and other hard
tool material.
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Figure 22.1 Effect of geometric factor in determining the theoretical finish (a) effect of nose
radius, (b) effect of feed, and (c) effect of end cutting edge angle.
Ri = f2 (22.1)
32( NR )
f = feed, NR = nose radius on the tool point
R a = rai R i (22.2)
Figure 22.2 Ratio of actual surface roughness to ideal surface roughness for several
materials.
Considerations
Quality, surface finish, dimension tolerance
Production rate,
Cost, operation, tooling, machinability
Flexibility, product changes
Characteristics, special manufacturing process