Technion – Israel Institute of Technology

Department of Mechanical Engineering

034030 Manufacturing Processes

6. Cutting
 2
Common Cutting Processes
 3
Factors Influencing Cutting Process
 4
Turning Operation
 5
Two-Dimensional Cutting Process

Cutting ratio:
to sinφ
r= =
tc cos(φ − α )
 6
Chip Formation

V Vs V
= = c
cos(φ − α ) cos α sinφ

Shear-strain rate:
Vs
γ& =
d
 Continuous with
narrow shear zone

Continuous with
built-up edge
Types of Chips

Segmented
7

Discontinuous
Surface finish in milling Surface finish in turning
Built-up Edge
8
 9
Chip Breakers
 10
Oblique Cutting
 11
Cutting Tool
 12
Forces Acting on a Cutting Tool

Fc -cutting force
Ft - thrust force
R - resultant force F = R sin β ; N = R cos β
Fs - shear force Fc = R cos(β − α ); Ft = R sin(β − α )
Fn- normal force Fs = R cos(φ + β − α ); Fn = R sin(φ + β − α )
F - friction force, F F + Fc tan α
N - normal force µ= = tan β = t
N Fc − Ft tan α
β- friction angle
 13
Thrust Force

AISI 1112
cold-rolled Ft = Fc tan(β − α )
steel

Note that at high rake angles,

the thrust force may be
negative, which has important
implications in the design of
machine tools and in
controlling the stability of the
cutting process
 14
Shear and Normal Stresses

Area of the shear plane:

w to
As =
sin φ
Average shear stress:
Fs Fs sinφ
τ= =
As w to
Average normal stress:
Fn Fn sin φ
σ= =
As w to
 15
Shear-Angle Relationships

Merchant model:
Fs Fc cos(φ + β − α ) sin φ
τ= =
As w to cos(β − α ) If we assume that β is independent of φ
dτ
= cos(φ + β − α ) cos φ − sin(φ + β − α ) sin φ = 0
dφ
α β
φ = 45o + −
2 2
Me
rch
ant
mo
de
l
 16
Specific Energy

Total power input in cutting = FcV

Total energy per unit volume of material removed :
FV F
ut = c = c = us + uf + use + um
w toV w to

Specific energy for shearing :

FsVs
us =
w toV

Specific energy for friction :

uf =
FVc
=
Fr (F sinα + Ft cos α ) r
= c
w toV w to w to

Surface energy, use, resulted from the for-

mation of 2 new surfaces can be neglected;
energy of momentum change , um, can be
significant at cutting speeds above 125 m/s.
 17
Temperatures in Cutting

• Sources of heat generation

◦ Shear zone
◦ Chip-tool interface
◦ Tool-workpiece interface

• Effects of the temperature rise

◦ Reduces the strength, hardness,
and wear resistance of the
cutting tool
◦ Causes dimensional changes in
the part being machined, making
control of accuracy difficult
◦ Can induce thermal damage to
the machined surface, affecting
its properties and service life
 18
Tool Wear Patterns
 19
Tool Wear

BUE
Rake face

Crater wear Flank face

Flank face

Rake face
Rake face
Flank wear
Thermal
Flank face cracking
 20
Flank Wear
 21
Taylor Tool-Life Curves

Taylor equation:

V T n = Const .
 22
Crater Wear

1) High-speed steel
2) C-1 carbide
3) C-5 carbide
 23
Chipping
 24
Tool-Condition Monitoring
 25
Machined Surfaces

• Factors affecting surface integrity

◦ Temperatures generated during
processing
◦ Residual stresses
◦ Metallurgical transformations
◦ Plastic deformation, tearing and
cracking

Produced by shaping
Produced by turning
 26
Properties of Cutting Tool Materials
 27
Hardness of Cutting Tools
 28
Coated Tools

Typical wear patterns of high-

speed-steel uncoated and Multiphase coatings on a
titanium-nitride coated tools tungsten-carbide substrate
 29
Carbide Inserts and Toolholders
 30
Insert Edge Strength
 31
Cubic Boron Nitride Inserts

Inserts with polycrystalline

cubic boron nitride tips (top
row), and solid-polycrystalline
cBN inserts (bottom row)
 32
Historical Tool Improvement
 33
Cutting Fluids

• Positive effects
◦ Reduce friction and wear, hence improving tool life and surface finish
◦ Reduce forces and energy consumptions
◦ Cool the cutting zone, thus reducing workpiece temperature and
distortion and improving tool life
◦ Wash away chips
◦ Protect the newly machined surfaces from environmental corrosion

• Negative effects
◦ Increase the extent of alternate heating and cooling in interrupted
cutting operations, such as milling, and can cause thermal fatigue
◦ May cause the chip to become curlier, thus concentrating the stresses
and heat near the tool tip, reducing the tool life
◦ Can represent biological and environmental hazard
 34
Proper Application of Cutting Fluids
 35
Characteristics of Machining
 36
Production Rates
 37
Lathe Operations
 38
Components of a Lathe
 39
Numerical-Control Lathe and Turret
 40
Collets
 41
Mandrels
 42
Turning Operation
 43
Right-Hand Tool Angles
 44
Cutting Speeds for Turning
 45
Typical CNC Parts
 46
Machining of Complex Shapes
 47
Cutting Screw Threads
 48
Chasers and Die for Thread Cutting
 49
Tapping
 50
Boring and Boring Mill
 51
Drilling and Reaming Operations
 52
Types of Drills
 53
Trepanning
 54
Reamers
 55
Drilling Machines
 56
Shapes Made with Multi-Tooth Tools
 57
Basic Types of Milling Cutters
 58
Peripheral Milling
 59
Peripheral Cutters
 60
Face Milling
 61
Face Milling Cutter
 62
Position of Cutter in Face Milling
 63
Effect of Insert Shape on Feed Marks
 64
Surface Features in Face Milling
 65
Edge Defects in Face Milling
 66
T-Slot Cutting and Shell Mill
 67
Ball Nose End Mills
 68
Column-and-Knee Milling Machines
 69
CNC Milling Machines
 70
Planing and Shaping
 71
Typical Parts Made by Broaching
 72
Broaching
 73
Chipbreaker Features on Broaches

Flat broach

Round broach
 74
Sawing Operation
 75
Saw Teeth
 76
Gear Cutting
 77
Parts Made on Machining Centers
 78
Horizontal-Spindle Machining Center
 79
Swing-Around Tool Changer
 80
CNC Turning Center
 81
Hexapod Machining Center
 82
Chatter and Vibration
 83
Economics of Machining

Optimum cutting speed:

C
Vo =
[(1 / n − 1)Tc ]n
Optimum tool life:
To = (1 / n − 1)Tc
where Tc is the tool
changing time