CUTTING FORCES and

POWER

Fig: (a) Forces acting on a cutting tool during 2-dimensional cutting. Note that the resultant force, R must
be collinear to balance the forces. (b) Force circle to determine various forces acting in the cutting zone.
 CUTTING FORCES and POWER
Knowledge of the cutting forces and power involved in
machining operations is important for the following reasons:
a. Machine tools can be properly designed to minimize
distortion of the machine components, maintain the desired
dimensional accuracy of the machined part, and help select
appropriate tool holders and work-holding devices.
b. The work piece is capable of withstanding these forces
without excessive distortion.
c. Power requirements must be known in order to enable the
selection of a machine tool with adequate electric power.

2
 CUTTING FORCES and POWER
Cutting force, Fc, acts in the direction of cutting speed, V, and
supplies energy required for cutting.
Thrust force, Ft , acts in a direction normal to cutting velocity,
perpendicular to WP. The resultant force, R can be resolved into two
components :
Friction force: F, along the tool-chip interface
Normal force: N, perpendicular to it.
F = R sin
N = R cos
R is balanced by an equal and opposite force along the shear plane
and is resolved into a shear force, Fs, and a normal force, Fn
Fs = Fc cos Ft sin
Fn = Fc sin + Ft cos
3
 Coefficient of Friction
Coefficient of friction between tool and chip:
F

N
Friction angle related to coefficient of friction as follows:

tan
The ratio of F to N is the coefficient of friction, , at the tool-chip
interface, and the angle is the friction angle.

F Ft Fc tan
Coefficien t of friction,
N Fc Ft tan

The coefficient of friction in metal cutting generally ranges from about

0.5 to 2.
4
 Shear Stress
Shear stress acting along the shear plane:
F
s
A
s

where As = area of the shear plane,

t ow
As
sin
Shear stress = shear strength of work material during
cutting
5
 CUTTING FORCES & POWER
Thrust Force
If the thrust force is too high or if the machine tool is not
sufficiently stiff, the tool will be pushed away from the surface
being machined.
This movement will, in turn, reduce the depth of cut, resulting in
lack of dimensional accuracy in the machined part, As the rake
angle increases and/or friction at the rake face decreases, this
force can act upward.
This situation can be visualized by noting that when = 0 (that is,
= 0), the resultant force, R, coincides with the normal force, N.
In this case, R will have a thrust-force component that is upward.

6
 Power required in Metal cutting
The Power consumed/ work done per sec in cutting: PC Fc v
The Power consumed/ work done per sec in shear: Ps Fs vs

The Power consumed/ work done per sec in friction: PF F vc

The total Power required:

P Pc Ps Pf

90
 Specific Energy
Specific Energy, ut ,is defined as the total energy per unit volume of
material removed.
FC v FC
ut
wt0v wt0
Where wt0vc is the MRR
Units for specific energy are typically N-m/mm3
Therefore is simply the cutting force to the projected area of cut.
If uf and us be specific energy for friction and specific energy for
shearing, then
Fvc Fs vs Fr Fs vs
ut u f us
wt0v wt0v wt0 wt0v
As the rake angle increases, the frictional specific energy remains
more or less constant, where as the shear specific energy rapidly
reduced.
91
Approximate Specific-Energy Requirements
in Cutting Operations
MATERIAL SPECIFIC ENERGY*
W-s/mm3 hp-min/in3
Aluminum alloys 0.4-1.1 0.15-0.4
Cast irons 1.6-5.5 0.6-2.0
Copper alloys 1.4-3.3 0.5-1.2
High-temperature alloys 3.3-8.5 1.2-3.1
Magnesium alloys 0.4-0.6 0.15-0.2
Nickel alloys 4.9-6.8 1.8-2.5
Refractory alloys 3.8-9.6 1.1-3.5
Stainless steels 3.0-5.2 1.1-1.9
Steels 2.7-9.3 1.0-3.4
Titanium alloys 3.0-4.1 1.1-1.5
* At drive motor, corrected for 80% efficiency; multiply the energy
by 1.25 for dull tools.

92
 Cutting Forces

Fig: (a) Forces acting on a cutting tool during 2-dimensional cutting. Note that the resultant force, R must
be collinear to balance the forces. (b) Force circle to determine various forces acting in the cutting zone.
10
 Merchants Circle Diagram
The following is a circle diagram.
Known as Merchants circle Chip

diagram, which is convenient to Fs

Tool

Clearance Angle
determine the relation between the Fc
( - )
various forces and angles. Fn
Work

In the diagram two force triangles Ft R

have been combined and R and R F

together have been replaced by R.
the force R can be resolved into two

components Fc and Ft. N

Fc and Ft can be determined by

force dynamometers.
R Fc Ft
The rake angle () can be measured from the tool, and forces F and N can
then be determined. The shear angle () can be obtained from its relation
with chip reduction coefficient. Now Fs & Fn can also be determined.
77
Merchants Circle Diagram

Chip
Tool
Fs
Fc Clearance Angle
( - )
Work
Fn
Ft R

78
The procedure to construct a Merchants
circle diagram
Chip
Tool
Fs
Fc Clearance Angle

Work
Fn
Ft R

79
 The procedure to construct a Merchants
circle diagram
Set up x-y axis labeled with forces, and the origin in the
centre of the page. The cutting force (Fc) is drawn
horizontally, and the tangential force (Ft) is drawn
vertically. (Draw in the resultant (R) of Fc and Ft.
Locate the centre of R, and draw a circle that encloses
vector R. If done correctly, the heads and tails of all 3
vectors will lie on this circle.
Draw in the cutting tool in the upper right hand quadrant,
taking care to draw the correct rake angle () from the
vertical axis.
Extend the line that is the cutting face of the tool (at the
same rake angle) through the circle. This now gives the
friction vector (F).
14
 The procedure to construct a Merchants
circle diagram
A line can now be drawn from the head of the friction vector,
to the head of the resultant vector (R). This gives the normal
vector (N). Also add a friction angle () between vectors R and
N. Therefore, mathematically, R = Fc+Ft = F + N.
Draw a feed thickness line parallel to the horizontal axis. Next
draw a chip thickness line parallel to the tool cutting face.
Draw a vector from the origin (tool point) towards the
intersection of the two chip lines, stopping at the circle. The
result will be a shear force vector (Fs). Also measure the shear
force angle between Fs and Fc.
Finally add the shear force normal (Fn) from the head of Fs to
the head of R.
Use a scale and protractor to measure off all distances (forces)
and angles.
15
 Relationship of various forces acting on the chip with the horizontal and
vertical cutting force from Merchant circle diagram
Frictional Force System
D
Chip
Tool
C Fs
Fc Clearance Angle
(90-)
E Fc O
( - )
( - )
(90-) G Work
Fn
Ft R Ft R

F F

B N N
A

F OA CB CG GB ED GB The coefficient of friction

F FC sin Ft cos tan
F
N
N AB OD CD OD GE
Where Friction angle
N FC cos Ft sin
82
Relationship of various forces acting on the chip with the horizontal and
vertical cutting force from Merchant circle diagram
Shear Force System
B
Chip
Tool
A Fs
Fs Fc Clearance Angle
(90-) Fc

C ( - )
O
( - ) Work
Fn
(90-) D Ft R
Fn
Ft R

F


N

FS OA OB AB OB CD Also:
FS FC cos Ft sin FN FS tan( )
FS RCos (
FN AE AD DE BC DE
FN FC sin Ft cos
83
Relationship of various forces acting on the chip with the horizontal and
vertical cutting force from Merchant circle diagram

Chip
Tool
Fs
Fc Clearance Angle

( - )
Work
F FC sin Ft cos
N FC cos Ft sin
Fn

Ft R

FS FC cos Ft sin
FN FC sin Ft cos
F

FN FS tan( )
N

Ft = R Sin (-)
Fc = R Cos ( )
84
 The Merchant Equation
Of all the possible angles at which shear deformation can
occur, the work material will select a shear plane angle
that minimizes energy, given by

45
2 2
Derived by Eugene Merchant.

Based on orthogonal cutting, but validity extends to 3-D

machining.
19
 The Merchant Equation
Assuming that the shear angle adjusts itself to minimize the cutting force, or
that the shear plane is a plane of maximum shear stress.
(21.3)

is the friction angle and is related to the coefficient of friction, , at the tool
chip interface (rake face):

From Eq (21.3), as the rake angle decreases

and/or the friction at the toolchip interface
increases, the shear angle decreases and the
chip becomes thicker,
Thicker chips mean more energy dissipation
because the shear strain is higher. As work
done during cutting is converted into heat,
temperature rise is also higher. 20
 Theory of Ernst and Merchant (1944)
Ernest and Merchant gave the relation

1
( )
4 2
Assumptions of the theory: M. Eugene Merchant
Tool edge is sharp.
The work material undergoes deformation across a thin shear
plane.
There is uniform distribution of normal and shear stress on the
shear plane.
The work material is rigid and perfectly plastic.
The shear angle adjusts itself to give minimum work.
The friction angle remains constant and is independent of .
The chip width remains constant.
95
What the Merchant Equation Tells Us

45
2 2

To increase shear plane angle

Increase the rake angle
Reduce the friction angle (or coefficient of friction)

22
 <--------TUGAS------>
Diketahui data-data pemotongan sebagai berikut:
NIM Ganjil NIM Genap
a. Cutting Force (Fc) = 115 N a. Cutting Force (Fc) = 110 N
b. Tangential Force (Ft) = 75 N b. Tangential Force (Ft) = 80 N
c. Rake angle () = + 30 c. Rake angle () = + 35
d. Tebal chip = 1 cm d. Tebal chip = 1 cm

1. Dengan menggunakan Merchant Circle, carilah friction vector (F),

Normal vector (N), shear angle (), Shear Force (Fs), Normal Force (Fn)
Friction angle (), koefisien gesek ()!Bandingkan antara metode
grafis dengan metode analitis.
2. Apabila v=25mm/s, vs=15mm/s, dan vc=12mm/s, Berapa Daya
Pemotongan?
3. Apabila MRR = 150 mm/s, Berapa spesific energy-nya?