Metal Cutting Theory
Metal Cutting Theory
Figure 9 ‑
Forces in metal
cutting: (a) forces
acting on the chip
in orthogonal
cutting
Vector addition of F and N = resultant R
Vector addition of Fs and Fn = resultant
R'
Forces acting on the chip must be in
balance:
R' must be equal in magnitude to R
R’ must be opposite in direction to R
R’ must be collinear with R
Coefficient of friction between tool and chip:
F
N
Friction angle related to coefficient of friction as follows:
tan
Shear stress acting along the shear plane:
Fs
S
As
where As = area of the shear plane
t ow
As
sin
Shear stress = shear strength of work material during cutting
Cutting Force and Thrust Force
Forces F, N, F , and F cannot be directly
s n
measured
Forces acting on the tool that can be measured:
◦ Cutting force Fc and Thrust force Ft
Figure9 ‑ Forces in
metal cutting: (b)
forces acting on the
tool that can be
measured
Equations can be derived to relate the
forces that cannot be measured to the
forces that can be measured:
F = Fc sin + Ft cos
N = Fc cos ‑ Ft sin
Fs = Fc cos ‑ Ft sin
Fn = Fc sin + Ft cos
Based on these calculated force, shear
stress and coefficient of friction can be
determined
Ofall the possible angles at which shear
deformation could occur, the work material
will select a shear plane angle which
minimizes energy, given by
45
2 2
Derived by Eugene Merchant
Based on orthogonal cutting, but validity
extends to 3-D machining
45
2 2
To increase shear plane angle
◦ Increase the rake angle
◦ Reduce the friction angle (or coefficient of
friction)
Higher shear plane angle means smaller shear
plane which means lower shear force
Result: lower cutting forces, power, temperature,
all of which mean easier machining
Fc v
HPc
33,000
Pc HPc
Puor HPu
MRR MRR
where MRR = material removal rate
Unit power is also known as the specific energy U
Pc Fc v Fc
U Pu
MRR vto w to w