Analysis of orthogonal metal cutting processes tyan. Sep 28, 20 the cutting condition when chip is expected to flow along the orthogonal plane is known as orthogonal cutting. An arbitrary lagrangian eulerian ale approach is used in this paper to model continuous threedimensional orthogonal and oblique steadystate metal cutting processes. Finite element simulation of orthogonal metal cutting.
Notes material properties are obtained from table 61 and table a 4 equation 64. Difference between orthogonal and oblique cutting orthogonal cutting in orthogonal cutting, the tool approaches the work piece with its cutting edge parallel to the uncut surface and at right angles to the direction of cutting. Summary the orthogonal metal cutting process for a controlled contact tool is simulated using a limit analysis. To make the results of the simulation agree the orthogonal cutting test better, the separation surface between the. Modeling of cutting force distribution on tool edge in. May 03, 2020 orthogonal and oblique cutting module 2 mechanics of machining lesson 6 notes edurev is made by best teachers of. Apr 15, 2004 an analysis of the chip geometry and the force system found in the case of orthogonal cutting accompanied by a type 2 chip has yielded a collection of useful equations which make possible the study of actual machining operations in terms of basic mechanical quantities. This process is most important since almost all the products get their final shape and size by metal removal, either directly or indirectly. What is the difference between oblique and orthogonal cutting. The slight difference in cutting speed between the inside and outside edge of the chip can be neglected. An eulerian reference coordinate is used to describe the steady state motion of the workpiece relative to a stationary cutting tool.
These tools are made of high speed steel so these tools can be operated at high rpm. In orthogonal cutting process, the cutting edge is perpendicular 90 degree to the direction of feed. In this work, cutting coefficient of aisi 1045 steel will be estimated using finite. In this only one sharp point is able to remove the material from the specimen.
For a given feed and depth of cutting, the force acts on a small area as compared with oblique cutting, so tool life is less. Pdf an ale threedimensional model of orthogonal, oblique. Simulation of orthogonal metal cutting operations is very popular nowadays and there are a lot of researchers studying on this subject. This report has been prepared to describe research work on understanding of metal sheet cutting punching and shearing carried out in the faculty of science, technology and arts at sheffield hallam university in 20182019. In this study, a process model for orthogonal cutting processes is proposed. As described in this chapter, since the second half this century, a lot work has been carried out for developing successful models of orthogonal metal cutting operations. With respect to the materials used, the cutting tool is divided into the. Fi orthogonal cutting is also known as two dimensional metal cutting in which the cutting edge is normal to the work piece. Metal cutting could be done either by a single point cutting tool or a multi point cutting tool. Cutting process variation market research conceptual design. Finite element simulation of the orthogonal metal cutting. Orthogonal machining twoforce model cutting tool geometry is simplified from the 3d oblique geometry to a 2d orthogonal geometry. An investigation into orthogonal and oblique cutting processes.
Difference between orthogonal and oblique cutting mecholic. Orthogonal cutting video, geometry, forces and power demonstration cutting equipmenttools. This tool is associated with the machine such as lathe and shaper machine. Orthogonal cutting in orthogonal cutting, the cutting edge inclination is zero and chip is expected to flow along the orthogonal. Removal of unwanted material in the form of chips in order to create a geometric shape. Then it is subjected to the specimen to perform the machining operation. Orthogonal cutting is a type of metal cutting in which the. Analysis of orthogonal metal cutting processes tyan 1992.
Less concentration of heat at cutting region compared to orthogonal cutting. In oblique cutting the angle between the cutting edge and the direction of the tool, motion is. No cutting tool is perfectly sharp, and in the idealized picture as shown in figure 2 the cutting edge is represented by a cylindrical surface joining the tool flank and tool face. For example, three dimensional cutting mostly used in turning operations. The basic and main difference between orthogonal cutting and oblique cutting is that in orthogonal cutting, the cutting edge of the tool is perpendicular to the direction of motion but in oblique cutting, the cutting edge makes an angle with the d. In a cutting process, the position of cutting edge of the tool with respect to the workpiece is important, based on which metal cutting process are classified into two categories. Oct 20, 2008 lecture series on manufacturing processes ii by prof. Cutting edge is 1 straight, 2parallel to the original plane surface on the work piece and 3perpendicular to the direction of cutting. Removal of unwanted material in the form of chips in order to. A special case of metal cutting, where the cutting. In orthogonal cutting operation, feed is at 90 degrees and it develops only two types of forces which are cutting force and thrust force which represents the 2d cutting action. In this type of cutting, the cutting edge is perpendicular to the direction of the motion of the tool.
The paper analyzes the relationships for calculating the cutting angle in oblique free cutting of metals, which were proposed earlier by some researchers. Effect of rake angle and feed rate on cutting forces in an. Figure 2015 orthogonal tube turning ott produces a twoforce cutting operation at speeds equivalent to those used in most oblique machining operations. For example, twodimensional cutting for square shoulder operation. In metal cutting theory, all operations performed with the wedgeshaped tool when a layer of metal is removed in the form of continuous or discontinuous chip can be conventionally divided into two general cases, termed orthogonal and oblique cutting. Simplified orthogonal machining inplane model of the cutting process. Orthogonal and oblique cutting module 2 mechanics of. Manufacturing technology orthogonal and oblique cutting orthogonal cutting the cutting edge of the tool is straight and perpendicular to the direction of motion. For the 2d orthogonal mechanistic model we will ignore the radial component f t a a c f. The cutting edge of tool is perpendicular to the work piece axis. In fourth part, straight angle cutting and oblique angle cutting process has been compared to find out impact of various parameters on straight angle cutting and shearing and how these may be differentiated. The shearing strain undergone by the metal during chip formation, and the velocities of shear and of chip flow are among. The basic principles are stated in the form of a primal optimization problem with an objective function subjected to constraints of the equilibrium equation, its static boundary conditions and a constitutive inequality.
Orthogonal cutting video, geometry, forces and power demonstration cutting equipmenttools design for manufacturing. Kim 3 orthogonal cutting in a lathe rake angle shear angle t o. Figure 1 shows the orthogonal cutting process basic elements. For the 2d orthogonal mechanistic model we will ignore the longitudinal component 14. According to the orthogonal cutting model, the specific cutting power is defined as the multiplication of the cutting force per unit crosssectional area and the cutting speed. View and download powerpoint presentations on orthogonal and oblique cutting ppt. Finite element simulation of orthogonal metal cutting using. Orthogonal cutting and oblique cutting mechanical education. Aug 22, 2014 manufacturing technology orthogonal and oblique cutting orthogonal cutting the cutting edge of the tool is straight and perpendicular to the direction of motion. Orthogonal cutting process an orthogonal metal cutting process for a controlled contact tool is depicted in figure 1 with labels illustrating the nomenclatures used in this paper.
Orthogonal cutting is a type of metal cutting angle in which the direction of the cutting tool is perpendicular to the cutting edge. The thermomechanical coupled model includes the effects of elastoplasticity, high strain and strain rates, heat generation and friction between the chip and the tool. Figure 1 depicts a typical oblique machining, such a process involves a 3 dimensional force system acting at the point of cutting which makes it complex for analysis and research work. In this paper, a finite element model of a twodimensional orthogonal metal cutting process is used to simulate the chip formation, cutting forces, stress, strain and temperature distributions. It is shown that from the standpoint of chip formation this cutting process is advisable to be treated as orthogonal free cutting with a tool whose rake is a function of the face sharpening angle and cutting edge inclination. Paul,department of mechanical engineering, iit kharagpur. Kim 2 cutting processes objectives product quality. An arbitrary lagrangian eulerian ale approach is used in this paper to model continuous threedimensional orthogonal and oblique steadystate metal cutting.
N metal cutting operation, the position of the cutting tool is important based on which the cutting operation is classified as orthogonal cutting and oblique cutting shown in g 1. Analysis of orthogonal metal cutting processes semantic scholar. This document is highly rated by students and has been viewed 372 times. Orthogonal cutting is a type of metal cutting in which the cutting edge of the. Generalized modeling of metal cutting mechanics by. The resultant too force in metal cutting is distributed over the areas of the tool that contact the chip and workpiece. On the mechanism of chip formation in oblique cutting of. In orthogonal cutting, the cutting edge of the tool is at right angles to the direction of the relative motion between the tool and the work piece. Mechanics of metal cutting consists of study of machining process and. Mechanics of metal cutting feed force main cutting force. Introduction and nomenclature of single point cutting tool.
The orthogonal metal cutting process for a controlled contact tool is simulated using a limit analysis theorem. There are many other differences which are describe below. Predictive analytical and thermal modeling of orthogonal. To machine the metal blow recommended cutting speeds. The basic and main difference between orthogonal cutting and oblique cutting is that in orthogonal cutting, cutting edge of the tool is perpendicular to the direction of motion but in oblique cutting the cutting edge make an angle with the direction of motion. Comparison between the orthogonal and oblique cutting. Difference between orthogonal and oblique cutting mech4study. In on national culture frantz fanon pdf metal cutting, international research in production.
Summary the orthogonal metal cutting process for a controlled contact tool is simulated. Yang department of mechanical engineering and applied mechanics, the university of michigan, ann arbor, michigan 48109, u. An ale threedimensional model of orthogonal and oblique metal cutting processes olivier pantale, roger rakotomalala, maurice touratier l. In machining like turning, shaping etc by single point turning tool, the metal removal. Cutters may have straight or helical teeth, resulting in orthogonal or oblique cutting action, respectively helical teeth lower tooth load, tool forces, chatter in conventional up milling the maximum chip thickness is at the end of the. The metal cutting is done by a relative motion between the work piece and the hard edge of a cutting tool.
The layer of the material with crosssection a b, is removed in the form of chips from the workpiece. An ale threedimensional model of orthogonal, oblique. Find powerpoint presentations and slides using the power of, find free presentations research about orthogonal and oblique cutting ppt. An ale threedimensional model of orthogonal, oblique metal cutting processes article pdf available in international journal of forming processes vol. Single point cutting tool is the cutting tool which has only one cutting edge. In machining, steel is the largest workpiece material used in the metal cutting area. There are two basic types of metal cutting by a single point cutting tool. Mrr, tool wear physics of cutting mechanics force, power tool materials design for manufacturing 2. A thermalviscoplastic constitutive equation associated with. An analysis of the chip geometry and the force system found in the case of orthogonal cutting accompanied by a type 2 chip has yielded a collection of useful equations which make possible the study of actual machining operations in terms of basic mechanical quantities. Machining can be defined as the process of removing material from a workpiece in the form of chips by a sharp cutting to leave the desired part shape. The chip flows in a direction normal to cutting edge of the tool.
Chapter 20 fundamentals of machining orthogonal machining. Orthogonal and oblique cutting tool engineering and. An investigation into orthogonal and oblique cutting. Pdf comparative study of chip formation in orthogonal and. Types of material used for making the cutting tool. Oct 23, 2016 the basic and main difference between orthogonal cutting and oblique cutting is that in orthogonal cutting, cutting edge of the tool is perpendicular to the direction of motion but in oblique cutting the cutting edge make an angle with the direction of motion. The cutting edge is inclined at an acute angle with normal to the cutting. Orthogonal and oblique cutting module 2 mechanics of machining lesson 6 notes edurev notes for is made by best teachers who have written some of the best books of. An eulerian reference coordinate is used to describe the steady. Lecture series on manufacturing processes ii by prof. Various cutting parameters including tool, metal sheet and cutting process parameters have been investigated for shearing. Turning forces for orthogonal model end view section aa note. In the oblique cutting model presented in this paper, under similarly defined crosssectional area, the average cutting force is multiplied by the cutting speed to.
601 583 1228 434 648 1131 849 949 1488 100 1294 482 928 97 59 114 1005 37 1114 817 1569 787 698 278 1169 1486 183 47 1517 54 365 1306 1011 1487 234 6 1019 1406