CH 21

Chapter 21
THEORY OF METAL MACHINING

Overview
of Machining
Technology
Theory of Chip Formation in Metal
Machining
Force Relationships and the
Merchant Equation
Power and Energy Relationships
in Machining
Cutting Temperature
ISE 316 - Manufacturing
Processes Engineering
Material Removal
Processes
A family of shaping operations, the common
feature of which is removal of material from a
starting workpart so the remaining part has the
desired shape
Categories:
Machining material removal by a sharp cutting
tool, e.g., turning, milling, drilling
Abrasive processes material removal by hard,
abrasive particles, e.g., grinding
Nontraditional processes - various energy forms
other than sharp cutting tool to remove material
Machining
Cutting action involves shear deformation of
work material to form a chip
As chip is removed, a new surface is exposed
Figure 21.2 (a) A crosssectional view of the machining process, (b)

tool with negative rake angle; compare with positive rake angle in (a)
Why Machining is
Important
Variety of work materials can be

machined
Most frequently applied to metals
Variety of part shapes and special

geometry features possible, such as:
Screw threads
Accurate round holes
Very straight edges and surfaces
Good dimensional accuracy and

surface finish
Disadvantages with
Machining
Wasteful
of material
Chips generated in machining are

wasted material, at least in the unit
operation
Time
consuming
A machining operation generally

takes more time to shape a given
part than alternative shaping
processes, such as casting, powder
metallurgy, or forming
Machining in the Manufacturing

Sequence
Generally
performed after other

manufacturing processes, such as
casting, forging, and bar drawing
Other processes create the general
shape of the starting workpart
Machining provides the final shape,
dimensions, finish, and special
geometric details that other
processes cannot create
Machining Operations
Most
important machining
operations:
Turning
Drilling
Milling
Other
machining operations:
Shaping and planing

Broaching
Sawing
Turning
Single point cutting tool removes material from a
rotating workpiece to form a cylindrical shape
Figure 21.3 (a) turning

Drilling
Used to create a round hole, usually by means of a
rotating tool (drill bit) that has two cutting edges
Figure 21.3 The three most

common types of machining
process: (b) drilling

Milling
Rotating multiple-cutting-edge tool is moved slowly

relative to work to generate plane or straight
surface
Two forms: peripheral milling and face milling
Figure 21.3 (c) peripheral milling, and (d) face milling

Cutting Tool Classification

1. Single-Point
Tools
One cutting edge

Turning uses single point tools
Point is usually rounded to form a
nose radius
2. Multiple
Cutting Edge Tools
More than one cutting edge

Motion relative to work usually
achieved by rotating
Drilling and milling use rotating
multiple cutting edge tools.
Figure 21.4 (a) A singlepoint tool showing rake face, flank, and tool
point; and (b) a helical milling cutter, representative of tools with
multiple cutting edges

Cutting Conditions in
Machining
The
three dimensions of a machining

process:
Cutting speed v primary motion
Feed f secondary motion
Depth of cut d penetration of tool below original
work surface
For
certain operations, material removal rate

can be found as
MRR = v f d
where v = cutting speed; f = feed; d = depth of cut
Cutting Conditions for Turning
Figure 21.5 Cutting speed, feed, and depth of cut for a turning
operation
Roughing vs. Finishing in

Machining
In production, several roughing cuts are
usually taken on the part, followed by
one or two finishing cuts
Roughing - removes large amounts of
material from the starting workpart
Creates shape close to desired geometry,
but leaves some material for finish cutting
High feeds and depths, low speeds
Finishing
- completes part geometry
Achieves final dimensions, tolerances, and

finish
Low feeds and depths, high cutting speeds
Machine Tools
A powerdriven machine that
performs a machining operation,
including grinding
Functions in machining:
Holds workpart
Positions tool relative to work
Provides power at speed, feed, and
depth that have been set
The
term is also applied to

machines that perform metal
Orthogonal Cutting Model

A simplified 2-D model of machining that describes
the mechanics of machining fairly accurately
Figure 21.6 Orthogonal cutting: (a) as a threedimensional process

Chip Thickness Ratio

to
r
tc
where r = chip thickness ratio; to = thickness of the
chip prior to chip formation; and tc = chip thickness
after separation
Chip
thickness after cut is always greater than

before, so chip ratio is always less than 1.0

Determining Shear Plane

Angle
Based
on the geometric parameters of the

orthogonal model, the shear plane angle
can be determined as:
r cos
tan
1 r sin
where r = chip ratio, and = rake angle

Figure 21.7 Shear strain during chip formation: (a) chip

formation depicted as a series of parallel plates sliding
relative to each other, (b) one of the plates isolated to
show shear strain, and (c) shear strain triangle used to
derive strain equation
Shear Strain
Shear strain in machining can be computed
from the following equation, based on the
preceding parallel plate model:
= tan( - ) + cot
where = shear strain, = shear plane

angle, and = rake angle of cutting tool

Figure 21.8 More realistic view of chip formation, showing shear

zone rather than shear plane. Also shown is the secondary shear
zone resulting from toolchip friction
Four Basic Types of Chip in

Machining
Discontinuous chip
2. Continuous chip
3. Continuous chip with Built-up
Edge (BUE)
4. Serrated chip
1.

Segmented Chip
Brittle work
materials (e.g., cast
irons)
Low cutting speeds
Large feed and
depth of cut
High toolchip
friction
Figure 21.9 Four types of chip

formation in metal cutting:
(a) segmented
Continuous Chip
Ductile work
materials (e.g., low
carbon steel)
High cutting speeds
Small feeds and
depths
Sharp cutting edge
on the tool
Low toolchip friction
formation in metal cutting:
(b) continuous

Continuous with BUE

Ductile
materials
Lowtomedium cutting
speeds
Tool-chip friction causes
portions of chip to adhere
to rake face
BUE formation is cyclical;
it forms, then breaks of
formation in metal cutting: (c)
continuous with builtup edge
Serrated Chip
Semicontinuous - sawtooth appearance
Cyclical chip formation
of alternating high
shear strain then low
shear strain
Most closely
associated with
difficult-to-machine
metals at high cutting
speeds
formation in metal cutting: (d)
serrated

Forces Acting on Chip

Friction force F and Normal force to friction N
Shear force Fs and Normal force to shear Fn
Figure 21.10
Forces in metal
cutting: (a) forces
acting on the chip
in orthogonal
cutting

Resultant Forces
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
Coefficient of friction between tool and chip:
F
N
Friction angle related to coefficient of friction as follows:
tan

Shear Stress
Shear stress acting along the shear plane:
Fs
S
As
where As = area of the shear plane
tow
As
sin
Shear stress = shear strength of work material during cutting

Cutting Force and Thrust Force

Forces F, N, Fs, and Fn cannot be directly measured
Forces acting on the tool that can be measured:
Cutting force Fc and Thrust force Ft
Figure 21.10 Forces

in metal cutting: (b)
forces acting on the
tool that can be
measured

Forces in Metal Cutting

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
The Merchant Equation

Of
all 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

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)

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
Figure 21.12 Effect of shear plane angle : (a) higher with a

resulting lower shear plane area; (b) smaller with a corresponding
larger shear plane area. Note that the rake angle is larger in (a),
which tends to increase shear angle according to the Merchant
equation
Power and Energy

Relationships
A
machining operation requires

power
The power to perform machining
can be computed from:
Pc = Fc v
where Pc = cutting power; Fc =
cutting force; and v = cutting
speed
Power and Energy

Relationships
In U.S. customary units, power is traditional expressed as
horsepower (dividing ftlb/min by 33,000)
Fcv
HPc
33,000
where HPc = cutting horsepower, hp

Power and Energy

Relationships
Gross power to operate the machine tool
Pg or HPg is given by
or
Pc
Pg
E
HPc
HPg
E
where E = mechanical efficiency of machine tool

Typical E for machine tools = 90%

Unit Power in Machining

Useful
to convert power into power per unit

volume rate of metal cut
Called the unit power, Pu or unit horsepower, HPu
or Pu
Pc
MRR
HPc
HPu
MRR
where MRR = material removal rate

Specific Energy in
Machining
Unit power is also known as the specific energy U
Pc
Fcv
Fc
U Pu
MRR vt ow t ow
Units for specific energy are typically Nm/mm3 or J/mm3 (inlb/in3)

Cutting Temperature
Approximately
98% of the energy

in machining is converted into
heat
This can cause temperatures to
be very high at the toolchip
The remaining energy (about 2%)
is retained as elastic energy in
the chip
Cutting Temperature
Several
analytical methods to calculate cutting

temperature
Method by N. Cook derived from dimensional
analysis using experimental data for various work
materials
0.333
0.4U vt o
T
C K
where T = temperature rise at toolchip interface; U = specific energy; v
= cutting speed; to = chip thickness before cut; C = volumetric specific
heat of work material; K = thermal diffusivity of the work material

Cutting Temperature
Experimental
methods can be used to

measure temperatures in machining
Most frequently used technique is the
toolchip thermocouple
Using this method, K. Trigger
determined the speedtemperature
relationship to be of the form:
T = K vm
where T = measured toolchip interface
temperature
Metal Cutting theory

Plastically
deform a material
using a hard tool in order to
obtain desired physical shape
and properties
Very complex phenomena
Essential for high precision; high
performance products

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Chapter 21

THEORY OF METAL MACHINING

Figure 21.2 (a) A crosssectional view of the machining process, (b)

Variety of work materials can be

Variety of part shapes and special

Good dimensional accuracy and

Chips generated in machining are

A machining operation generally

Machining in the Manufacturing

performed after other

Shaping and planing

Figure 21.3 (a) turning

Figure 21.3 The three most

ISE 316 - Manufacturing

Rotating multiple-cutting-edge tool is moved slowly

Figure 21.3 (c) peripheral milling, and (d) face milling

Cutting Tool Classification

One cutting edge

Cutting Edge Tools

More than one cutting edge

ISE 316 - Manufacturing

three dimensions of a machining

certain operations, material removal rate

Cutting Conditions for Turning

Roughing vs. Finishing in

- completes part geometry

Achieves final dimensions, tolerances, and

term is also applied to

Orthogonal Cutting Model

Figure 21.6 Orthogonal cutting: (a) as a threedimensional process

Chip Thickness Ratio

thickness after cut is always greater than

ISE 316 - Manufacturing

Determining Shear Plane

on the geometric parameters of the

ISE 316 - Manufacturing

Figure 21.7 Shear strain during chip formation: (a) chip

where = shear strain, = shear plane

ISE 316 - Manufacturing

Figure 21.8 More realistic view of chip formation, showing shear

Four Basic Types of Chip in

ISE 316 - Manufacturing

Figure 21.9 Four types of chip

ISE 316 - Manufacturing

Continuous with BUE

ISE 316 - Manufacturing

Forces Acting on Chip

ISE 316 - Manufacturing

ISE 316 - Manufacturing

ISE 316 - Manufacturing

Cutting Force and Thrust Force

Figure 21.10 Forces

ISE 316 - Manufacturing

Forces in Metal Cutting

can be derived to relate

on these calculated force,

The Merchant Equation

all the possible angles at which shear