Module I
Metal Cutting
Problems on Merchant Circle
Terminology used in Merchant Circle
FP – Cutting force
FQ – Thrust force or feed force
Fs – Shear Force
Ns – Force perpendicular to shear plane
FC – Normal force
NC- Force perpendicular to tool face
- Tool rake angle
- Friction angle
- Shear angle
Mechanics of orthogonal cutting
Cutting forces
Chip
C Nc
Fc
B
Ns FS R
FP
FQ
R’ A
-
Free body diagram of chip
Mechanics of orthogonal cutting
Composite cutting force circle
(Merchant circle [1945])
Chip
Tool
FS
FP
-
N S
FQ R
FC
NC
Solved Examples - 1
1. During orthogonal cutting a bar of 90 mm diameter is
reduced to 87.6 mm. If the mean length of cut chip is 88.2
mm and rake angle is 15⁰, calculate
a. Cutting ratio
b. Shear angle
Answer
Given t = lc = 88.2 mm, = 15ᵒ
(a) To find Cutting ratio (r)
Cutting ratio (r ) = 0.3162
Solved Example – 1 (contd..)
(b) To find Shear angle ()
Solved Example - 2
The following data relate to the orthogonal cutting of a
component
• Feed force 900 N
• Cutting force 1800 N
• Chip thickness ratio 0.26
• Tool rake angle 12⁰
Determine
a. Compression and shear forces
b. Coefficient of friction of the chip on the tool face
Answer
Given FP = 1800 N, FQ = 900 N, r = 0.26, = 12ᵒ
(a) To find Compression (FC) and Shear force (FS)
We know that
Solved Example – 2 (contd..)
We know that
Use the above two formulae and get the answer
(b) To determine Coefficient of friction () of the chip
on the tool face
We know that
Solved Example 3
The following data relate to orthogonal cutting of mild steel part
– Cutting speed 195 m/min
– Tool rake angle 12ᵒ
– Width of cut 1.75 mm
– Uncut chip thickness 0.25 mm
– Average coefficient of friction between the tool and chip 0.52
– Shear stress of the work material 385 N/mm2
Calculate
(a) Shear angle ()
(b) Cutting (FP) and thrust (FQ) component of the machining
Answer
Given V = 195 m/min, =12ᵒ, b = 1.75 mm, t = 0.25 mm, = 0.52,
= 385 N/mm2
Solved Example 3 (contd..)
(a) To determine Shear angle ()
We know that
b = 27.5ᵒ
Using Merchant’s equations
f = 37.25ᵒ
(b) To determine Cutting (FP) and thrust (FQ) component
We know that
Also
Problems on Tool Wear
Solved Example 4
A cutting tool, cutting at 22 m/min, gave a life of 1 hour
between re-grinds when operating on roughening cuts with
mild steel. What will be its possible life when engaged on light
finishing cuts. Take n = 1/8 for roughening and 1/10 for
finishing cuts in the Taylor’s equation VTn=C.
Answers
Given V = 22 m/min, Tr = 1 hour = 60 min, n = 1/8 and 1/10
for roughening and finishing respectively
Probable life, Light finishing cuts (Tf)
We know that, Taylor’s equation
For roughening cut
For finishing cut
From the above two equation, we get
Solved Example 5
Calculate the percentage change in cutting speed required to
give 60% reduction in tool life. Take n = 0.22
Answer
We know that, Taylor’s equation
Inference: This means that V2 should be 22.3% higher than V1
for the required % reduction in tool life
Solved Example 6
During straight turning of a 24 mm diameter steel bar at 300
rpm (revolutions per minute) with an HSS tool, a tool life of 9
min was obtained. When the same bar was turned at 250 rpm,
the tool life increased to 48.5 min. what ill be the tool life at a
speed of 280 rpm.
Answer
Given D = 24 mm, N1 = 300 rpm, T1 = 9 min
N2 = 250 rpm, T2 = 48.5 min
N3 = 280 rpm, T3 = ?
We know that, Cutting speed
Solved Example 6 (contd..)
To calculate, Tool life at 280 rpm
We know that, Taylor’s equation
From
T3 = 17.06 min