THEORY OF METAL CUTTING

COURSE CONTENTS

• Machining Processes and Machine Tools

• Materials and Geometry of Cutting Tools
• Mechanics of Machining Processes
• Tool Wear, Tool Life and Machinability
• Grinding and other abrasive Machining Processes
• Non conventional Machining Processes
• Economics of Machining Processes
 Text and Reference
Books
1. “Fundamentals of Modern Manufacturing:
Materials, Processes, and Systems, 5/E”, Mikell
Groover, John Wiley & Sons 2013.
2. “Manufacturing Engineering & Technology, 6/E”
S. Kalpakjian and S. Schmid, 2009.
3. “Fundamentals of Metal cutting and Machine
Tools” B.I.Juneja, G.S. Sekhon, and N. Seth, 2008.
 Introduction – Metal Cutting
Metals are shaped into usable forms through various processes
NO-CUTTING SHAPING (FORMING) No chip formation takes place, and
the metal is shaped under the action of heat, pressure or both Ex:
Forging, Spinning, Rolling, Drawing, Extruding, etc.
CUTTING SHAPING The components are brought to the desired shape
size by removing the unwanted material from the parent metal in the
form of chips through machining. Ex: Turning, Boring, Milling, Drilling,
Shaping, Planning, Broaching, Sawing, Grinding etc
 Machined parts are classified as (a) Rotational, or
(b)Non rotational, shown here by block and flat parts.
Generating shape in machining: (a) straight turning, (b) taper turning, (c)
contour turning, (d) plain milling, and (e) profile milling
Common Machining
Processes

Some examples of common machining processes.

Machining operations other than turning that are performed on a lathe: (a) facing, (b)
taper turning, (c) contour turning, (d) form turning, (e) chamfering, (f) cutoff, (g)
threading, (h) boring, (i) drilling, and (j) knurling.
Forming to create shape in machining: (a) form turning, (b)
drilling, and (c) broaching
Combination of forming and generating to create shape: (a)
thread cutting on a lathe, and (b) slot milling
Diagram of an engine lathe, indicating its principal components
Four work holding methods used in lathes: (a) mounting the work
between centers using a dog, (b) three-jaw chuck, (c) collet, and (d)
faceplate for noncylindrical work parts.
 (a) Type of part produced on a six-spindle automatic bar machine; and
(b) sequence of operations to produce the part: (1) feed stock to stop,
(2) turn main diameter, (3) form second diameter and spotface, (4) drill,
(5) chamfer, and (6) cutoff.
Two forms of horizontal boring: (a) boring bar is fed into a
rotating work part, and (b) work is fed past a rotating boring bar.
A vertical boring mill
 Two hole types: (a) through hole
and (b) blind hole

Machining operations related to

drilling: (a) reaming, (b) tapping, (c)
counter boring, (d) countersinking,
(e) center drilling, and (f) spot
facing.
Upright drill press

Radial drill press

Two basic types of milling operations: (a) peripheral or plain milling and (b)
face milling
Peripheral milling: (a) slab
milling, (b) slotting, (c) side
milling, (d) straddle milling,
and (e) form milling

Two forms of peripheral milling

operation with 20-tooth cutter:
(a) up milling, and (b) down
milling
Face milling: (a) conventional face milling, (b) partial face milling, (c)
end milling, (d) profile milling, (e) pocket milling, and (f) surface
contouring
Basic objectives of economic and efficient
machining practice
1. Quick Metal Removal (MRR)
2. High class surface finish
3. Economy in tool cost
4. Less power consumption
5. Economy in the cost of replacement and
sharpening of tools
6. Minimum deal time of machine tools
Basic Elements of Machining
Finite Element Simulation of Orthogonal Cutting Process
 Machining Parameters
• Cutting Speed V = π D N /1000 m/min
• Feed rate f = F/N mm/rev
• Uncut chip thickness t = f cos(γs) mm
• Depth of cut d = b cos(γs) mm
• Area of uncut chip Ac = f d mm2
• Metal Removal Rate (MRR) Zw = 1000 f d V mm3/min
• No. of passes m = depth of stock to be removed/depth of cut per pass
• Time of cutting per path Tc = L / (f N) min
• Machining Time Tm = (L + la) / (f N) min
Where; D is the workpiece diameter in mm, N the rotational speed of the workpiece in

rpm, F longitudinal feed rate in mm/min , f feed rate in mm/rev, γs the side cutting edge
angle in degree, b the cutting edge engagement in mm, m no off passes, L the length of
workpiece in mm. la the approach length in mm.
 Evaluate the Machining Parameters
Example 1: Evaluate the machining parameters for the case of cylindrical turning of a 25 mm
diameter brass bar at a spindle speed of 900 rpm. Depth of cut 3 mm, longitudinal feed rate = 20
cm/min, length of workpiece = 50 cm, stock to be removed = 6 mm and side cutting angle of the
tool 30 degree.

Solution: Cutting speed v = π×25×900 /1000 = 70.68 m/min

Feed rate f = 20×10/900 = 0.222 mm/rev
Uncut chip thickness t = f cos(30)= 0.192 mm
Cutting edge engagement b = 3/ cos(30)= 3.46 mm
Area of uncut chip Ac = 0.222×3= 0.666 mm2
Metal Removal Rate (MRR) Zw = 1000×0.222×3×70.68 = 4.71×105 mm3/min
No. of passes m = 6/3= 2 passes
Total Machining Time Tm = 2 / (0.222×900) min
Classification of machining processes. AJM, abrasive jet machining; WJM, water jet
machining; USM, ultrasonic machining; AFM, abrasive flow machining; MAF, magnetic
abrasive finishing; CHM, chemical machining; ECM, electrochemical machining; EDM,
electrodischarge machining; LBM, laser beam machining; PBM, plasma beam machining
Classification of machine tools for traditional machining technology
Classification of machine tools for nontraditional machining technology
Two basic types of knee-and-column milling machine: (a) horizontal and
(b) vertical.
Special types of knee-and-column milling machine: (a) universal—overarm,
arbor, and cutter omitted for clarity: and (b) ram type.
Simplex bed type milling machine horizontal spindle.
(a) Shaping, and (b) planing
A universal machining center. Capability to orient the work
head makes this a five-axis machine.
CNC four-axis turning center.
Operation of a mill-turn center: (a) example part with turned, milled, and
drilled surfaces; and (b) sequence of operations on a mill-turn center:
(1) turn second diameter, (2) mill fl at with part in programmed angular
position, (3) drill hole with part in same programmed position, and (4)
cutoff.
Components of a shaper
Open side planer
Double housing planer
Types of shapes that can cut by shaping and planing: (a) V-groove,
(b) square groove, (c) T-slot, (d) dovetail slot, and (e) gear teeth.
The broaching operation
Work shapes that can be cut by: (a) external broaching, and (b) internal
broaching. Cross-hatching indicates the surfaces broached.
Three types of sawing operations: (a) power hacksaw, (b) bandsaw
(vertical), and (c) circular saw.
Thread milling using a form-milling cutter.
Form milling of gear teeth on a starting blank.
Gear hobbing
Gear shaping
Comparison of cutting speeds used in conventional versus high-speed
machining for selected work materials.