Michael David Bryant 9/14/06

ME 392Q Manufacturing Processing: Unit Processes University of Texas at Austin 1

PHYSICS OF MACHINING


o Cutting ubiquitous manufacturing
process

o Formulate model of cutting physics to
predict tool forces dependency on
! Materials
! Cutting speed
! Geometry
! Conditions


Approach: Merchants cutting model
o Kinematics: relate geometric & motion
variables
o Dynamics: stationary system (quasi-
equilibrium)
! Balance tool forces
! Power considerations
o Assembly

2

Merchants cutting model

o Simplifying assumptions
! Thin shear zone (!w -> 0)
! Type II, continuous chip
! Orthogonal cutting (edge
perpendicular to cutting velocity)
! Perfectly sharp cutting edge
! Plastic flow at shear zone
! Shearing in plane
! Incompressible chip

tool
workpiece
flank or relief
rake face
chip
v
shear zone


3

o Weakness of assumptions
! Dull cutter
! Deformation ZONE, not line
! Metals strain harden
! Most cutting is oblique (edge not
perpendicular to cutting velocity)

4

Geometry near shear zone

tool
rake
face
chip
v
shear
line
uncut chip
L
s
h
!
"
h
c
v
c
y
x
h
cx
"
#
!/2 - "

o h depth of cut
o L
s
length of shear zone
o " shear zone angle
o h
c
thickness of cut chip
o # rake angle
o v velocity, uncut chip
o v
c
velocity of chip

h
cx
= L
s
cos ! + h tan "

!
h
cx
= h
cos"cos# + sin# sin"
sin"cos#
=
h
c
cos#


note: h = L
s
sin !

!
h
c
= h
cx
cos"

5

Definition: Cutting ratio r = h/h
c

!
r =
h
h
c
=
sin"
cos"cos# + sin# sin"
=
sin"
cos " $#
( )



!
=
1
cot "cos# + sin#


< 1, for small ", #

Incompressible chip:

" final volume = initial volume

" dV
f
/dt = dV
i
/dt


" v h b = v
c
h
c
b

! b out of plane thickness

" chip velocities: v
c
< v


!
v
c
v
=
h
h
c
= r <1



6
Geometry

tool
rake
face
chip
v
shear
zone
uncut chip
h
!
"
h
c
v
c
y
x
#
L
c


o L
c
length of tool-chip contact zone
o h depth of cut
o L
s
length of shear zone
o " shear zone angle
o h
c
thickness of cut chip
o # rake angle
o $ relief angle
o v velocity, uncut chip
o v
c
velocity of chip

7
Tool forces: Free Body Diagram, Chip
chip
!
"
y
x
F
c
F
s
R
F
n
F
f
R!

o F
c
compressive force, workpiece on chip
o F
s
shear force, workpiece on chip
o R resultant force, F
c
& F
s

o F
n
normal force, tool on chip
o F
f
friction force, tool on chip
o R resultant force, F
n
& F
f

o " shear zone angle
o # rake angle

Assumptions:
o stationary system (steady velocities)
" dv/dt = dv
c
/dt = 0 (no accelerations)

" ! F = 0 (quasi-equilibrium)

o R & R act along same line (no moments)

8
chip
!
"
y
x
F
c
F
s
R
F
n
F
f
R!
s
c
f
n
!
#/2 $"
!


angle = #/2 ! (#/2 - ") = " $ !

equilibrium:

! F
s
= 0 ! F
c
= 0

F
s
- (F
n
)
s
- (F
f
)
s
= 0 F
c
+ (F
n
)
c
- (F
f
)
c
= 0

F
s
= (F
n
)
s
+ (F
f
)
s
F
c
= - (F
n
)
c
+ (F
f
)
c


9
Constitutive Equations

o Tool-chip rubbing interface:

Coulomb friction F
f
= F
n


Friction angle: %

= F
f
/F
n
= tan %




o Shear zone:

Rigid-Perfectly Plastic material

all yielding, stress & = &
s



F
n
F
f
R!
!
stress !
strain "
!
s
"
p
stress !
strain "
!
s
"
e
"
p
F
f
= F
n
= F
n
tan %
F
s
= &
s
A = &
s
L
s
b = &
s
bh/sin !

10







angle = " $ !






(F
n
)
c
= F
n
sin (" $ !)
= - F
n
sin (! $ ")

(F
n
)
s
= F
n
cos (" $ !)

(F
f
)
c
= F
f
cos (" $ !)

(F
f
)
s
= F
f
sin (" $ !)
= - F
f
sin (! $ ")

chip
!
"
y
x
F
c
F
s
R
F
n
F
f
R!
s
c
f
n
!
#/2 $"
!
F
n
F
f
s
c
f
n
! "#
! "#
(F
n
)
c
(F
n
)
s
(F
f
)
s
(F
f
)
c
! "#

11
o Combine:
(F
n
)
c
= - F
n
sin (! $ ")
(F
n
)
s
= F
n
cos (! $ ")

(F
f
)
c
= F
f
cos (! $ ") = F
n
cos (! $ ")
(F
f
)
s
= - F
f
sin (! $ ") = - F
n
sin (! $ ")

o Substitute:
F
s
= (F
n
)
s
+ (F
f
)
s
= F
n
[cos(! $ ") sin(! $ ")]

o Solve:
!
F
n
=
"
s
bh
sin#
1
cos(# $%) $sin(# $%)


o Substitute:
F
c
= -(F
n
)
c
+(F
f
)
c
= F
n
[sin(! $ ")+ cos(! $ ")]


!
=
"
s
bh
sin#
sin(# $%) + cos(# $%)
cos(# $%) $sin(# $%)



!
=
"
s
bh
sin#
sin(# $%) + tan&cos(# $%)
cos(# $%) $tan&sin(# $%)



!
=
"
s
bh
sin#
cos$sin(# %&) + sin$cos(# %&)
cos$cos(# %&) %sin$sin(# %&)


12

!
F
c
=
"
s
bh
sin#
sin(# $% + &)
cos(# $% + &)
=
"
s
bh
sin#
tan(# $% + &)



o Obtain resultant force:

!
R = F
s
2
+ F
c
2
=
"
s
bh
sin#
1+ tan
2
(# $% + &) =
"
s
bh
sin#
sec
2
(# $% + &)





!
R =
"
s
bh
sin#
1
cos(# $% + &)



Note: " is still unknown


13

Power in:

P
in
= F
cut
v







o F
c
compressive force, workpiece on chip
o F
s
shear force, workpiece on chip
o R resultant force
o F
cut
cutting force, in x-direction
o F
thrust
thrust force, in y-direction

F
cut
= F
s
cos ! + F
c
sin !


!
=
"
s
bh
sin#
cos# +
"
s
bh
sin#
sin(# $% + &)
cos(# $% + &)
sin#



!
=
"
s
bh
sin#
1
cos(# $% + &)
cos#cos(# $% + &) + sin#sin(# $% + &)
[ ]



!
= Rcos[(" #$ + %) #"]



!
F
cut
= Rcos(" #$)

!
F
thrust
= Rsin(" #$)


chip
!
"
y
x
F
c
F
s
F
n
F
f
F
cut
F
thrust
R
v

14


o Note: " is still unknown

o " from minimization of power

nature dislikes concentrations of energy


!
P
in
= F
cut
v = R(")cos(# $%)v


o minimize (by choice of !)


!
R(") =
#
s
bh
sin"
1
cos(" $% + &)


o same as maximizing


!
D(") = sin"cos(" #$ + %)


!
0 =
"D(#)
"#
= cos#cos(# $% + &) $sin#sin(# $% + &)


"
!
cos(2" #$ + %) = 0


"
!
2" #$ + % = n
&
2


15
"
!
2" #$ + % =
&
2


"
!
" =
# $%
2
+
&
4


o " shear zone angle
o # rake angle
o % friction angle ( = arctan )