08_1_Cutting.ppt.pptVIP

Machining Manufacturing Processes ? 2012 Su-Jin Kim GNU Manufacturing Processes  Cutting (Machining) ???? Su-Jin Kim School of Mechanical Engineering Gyeongsang National University Cutting Cutting mechanics Tool wear Tool material Turning, Turning center Milling, Machining center Cutting mechanics (????) Chip formation ? Shear break off Cutting force = Specific energy x Area Chatter (vibration) Cutting temperature Tool wear Tool life equation Chip Formation (???) Chips are produced by the shearing taking place along a shear plane. Cutting Force (????) According to maximum-shear-stress criterion, yielding occurs when the max shear stress within an element is equal to or exceeds a critical value (shear yield stress). Tool (Assume no friction) Fc σ1 Stock σ σ1 τ τ Ф Mohr’s circle Shear angle Shear plane Cutting Force (Shear force theory) Shear Force = Shear Stress * Shear Area Shear Area = Width x Depth / sin (Shear Angle) t0 φ t0 /sin(φ) Tool w Fs Cutting Force (Theory) Resultant force = Shear force / cos (shear angle + friction angle – rake angle) Tool α β-α ф Workpiece Fs R β Chip Cutting Force (Theory) Cutting force = Resultant force x cos (friction angle – rake angle) Shear angle = pi/4 + rake angle/2 – friction angle/2 Tool α β-α ф Workpiece Fc R Chip Cutting Force Rake angle ↑ ? shear angle ↑, cutting force ↓ ? chip thickness ↓, cooler chip ↓ Rake angle ↑ ? tool section ↓ ? strength at cutting edge ↓, heat conductivity ↓ Relief angle ↑ ? friction ↓ ? tool life ↑, surface quality ↑ Relief angle ↑ ? strength at cutting edge ↓ Nose radius ↓ ? heat ↓, surface quality ↑ Force ↑ yield stress of stock ↑, cut depth ↑, cut width ↑ Rake angle,α Relief angle, r + Shear angle, φ Nose radius Cutting Force Approximation (???) Cutting force ≈ Specific cutting energy(??????) x Cutting area Fc ≈ ut Ac Cutting power = force x velocity P = Fc V Tool Stock Ac Fc Material Specific cutting energy (GPa) Tensile strength (MPa) Aluminum alloys 0.4-1.1 480 Copper