Orthogonal Cutting in Production Engineering
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pk09nick02Orthogonal Cutting in Production Engineering
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Powered by AIDominant wear patterns include flank wear, crater wear, and notch wear. Flank wear affects surface finish and increases cutting forces, influencing energy consumption. Crater wear impacts tool strength and can lead to catastrophic failure, altering chip flow dynamics. Notch wear arises at specific locations due to relative movement, contributing to tool weakening .
Built-up edge (BUE) forms when material adheres to the tool's cutting edge during machining, altering the effective rake angle and causing surface finish degradation. BUE typically occurs at lower cutting speeds and high friction conditions. It can paradoxically protect the tool from wear initially, but its irregularity leads to erratic surface finish and dimensional accuracy issues .
Using Merchant's analysis, the shear plane angle (phi) is calculated using the formula: phi = 45 + (rake angle/2) - (friction angle/2), where the friction angle is derived from the tangent of the shear force to friction force ratio. This analysis assumes ideal shearing without material variability .
Methods include dynamometers for force measurement, offering precision but are costly and complex. Tool temperatures can be measured via infrared thermography or embedded thermocouples; infrared is non-intrusive and fast but less precise for exact point temperatures, whereas thermocouples provide precise local readings but require tool modification .
Orthogonal cutting is a machining process where the cutting edge of the tool is perpendicular to the cutting direction, simplifying the analysis of cutting forces and thermal distribution. It is important because it provides a clearer understanding of the mechanics of cutting, facilitating the development of analytical models for predicting cutting performance and tool life .
Cutting fluids enhance machining by reducing friction and acting as coolants, flushing away chips, and protecting surfaces from corrosion. Their effectiveness is sensitive to factors such as fluid composition, application method, and cutting conditions, such as speed and tool material .
Increasing the clearance angle reduces the contact between the tool flank and the workpiece, minimizing friction and temperature, which prolongs tool life between re-grinds. Specific percentage increase depends on material properties and cutting conditions but generally results in significant tool life extension due to reduced wear rates .
The rake angle affects shear plane angle, chip formation, and cutting forces. A positive rake angle generally reduces cutting force and tool wear by facilitating easier chip flow, but can weaken the tool edge. The clearance angle is critical for minimizing tool-workpiece contact, reducing friction and wear. An optimal clearance angle improves tool life and surface finish .
Merchant's force circle is a graphical representation that correlates cutting force components, shear forces, and friction forces. By resolving forces into a circle, equations for shear force (F_s) and friction force (F_f) can be derived in terms of cutting forces, rake angle, and shear angle. Assumptions include uniform stress and negligible tool wear .
Desirable characteristics include high hardness at elevated temperatures, toughness, wear resistance, and chemical stability. Carbides offer excellent toughness and wear resistance due to their composite structure. CBN excels at high hardness and thermal stability, making it ideal for high-speed machining of hard materials .