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08cutting_2_6_f - Cutting processes 2.008 Design...

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1 2.008-spring-2004 S.Kim 1 2.008 Design & Manufacturing II Spring 2004 Metal Cutting II 2.008-spring-2004 S.Kim 2 Cutting processes Objectives Product quality: surface, tolerance Productivity: MRR , Tool wear Physics of cutting Mechanics Force, power Tool materials Design for manufacturing 2.008-spring-2004 S.Kim 3 Orthogonal cutting in a lathe Rake angle Shear angle T o : depth of cut Shear plane Assume a hollow shaft 2.008-spring-2004 S.Kim 4 Velocity diagram in cutting zone ( ) ( ) ( ) φ sin c V α cos s V α φ cos V = = ( ) ( ) α φ cos φ sin r c t o t V c V = = = ( ) ( ) α φ cos φ Vsin c V = ( ) ( ) α φ cos φ sin r c t o t V c V = = = Cutting ratio: r <1 2.008-spring-2004 S.Kim 5 E. Merchant’s cutting diagram α φ R F t F c F n F s F N α β Source: Kalpajkian F t F c β−α 2.008-spring-2004 S.Kim 6 ( ) ( ) α ) β Rcos( φ φ sin t F φ cos c F s F + = = ( ) ( ) φ cos t F φ sin c F n F + = ( ) β sin R F = ( ) β cos R N = ( ) β tan μ = Angle Friction β = 2 μ 0.5 : Typcially < < FBD of Forces ( ) ( ) α tan t F c F α tan c F t F N F μ + = = ( ) α - β sin R Ft = ( ) α - β cos R Fc =
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