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Fig 38: Continuous with built-up edge chips
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Decreasing the depth of the cut, increasing the rake angle, and using a sharp tool and an effective cutting fluid reduce the tendency for the BUE to form Although the BUE is generally undesirable, a thin, stable BUE is usually regarded as being desirable because it protects the tool s surface Discontinuous chips Discontinuous chips consist of segments that may be firmly or loosely attached to one another Discontinuous chips usually form under the following conditions: Brittle workpiece materials, because they do not have the capacity to undergo the high shear strains developed while cutting Materials that contain hard inclusions and impurities Very low or very high cutting speeds Large depths of cut and low rake angles Low stiffness of the machine tool Lack of an effective cutting fluid Because of the discontinuous nature of chip formation, forces continually vary during cutting Fig 39: Discontinuous chips The stiffness of the cutting-tool holder and the machine tool is important in cutting with discontinuous chip as well as serrated-chip formation This affects the surface finish and the dimensional accuracy of the machined part and may damage or cause excessive wear of the cutting tool Chip formation results if the material separates at or close to the tool tip In general, a nonlinear relation between the cutting force and the depth of the cut can be expected owing to the tool
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Fig 310: Forces equal and opposite in magnitude in metal cutting
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geometry, the material properties and the temperature rise in the contact zone Lee and Schaffer developed a model based on the idea that the material shears plastically along a plane to form the chip Their model assumed the material to be ideally plastic, that is, the yield stress did not depend on the strain rate and the strain (no hardening), and elastic stresses and strains were not considered [6] It is important to have knowledge of the forces and power involved in cutting operations for the following reasons [7]: 1 Power requirements have to be determined so that a motor of a suitable capacity can be installed in the machine tool 2 Data on forces are necessary for the proper designing of machine tools for cutting operations that avoid an excessive distortion of the machine elements and maintain the desired tolerances for the machined part 3 The work piece s ability to withstand the cutting forces without any excessive distortion has to be determined in advance The forces acting on the tool in orthogonal cutting are shown in Figure 310 The cutting force, Fc, acts in the direction of the cutting speed, V, and supplies the energy required for cutting The thrust force, Ft, acts in the direction normal to the cutting velocity, that is, perpendicular to the work piece These two forces produce the resultant force, R The resultant force can be resolved into two components on the tool face: a friction force, F, along the tool-chip interface, and normal force, N, perpendicular to it The resultant force is balanced by an equal and opposite force along the shear plane and is resolved into a shear force, Fc, and normal force, Fn The coefficient of friction in metal cutting generally ranges from about 05 to 20, thus indicating that the chip encounters a considerable frictional resistance while climbing up the face of the tool Although the magnitude of the forces in actual cutting operations is generally of the order of a few hundred newtons, the local stresses in the cutting zone and the pressures on the tool are very high because the contact areas are very small A general discussion of the forces acting during metal cutting is presented by using an example of a typical turning operation When a solid bar is turned, there are three forces acting on the cutting tool [3]: Tangential Force This acts in a direction tangential to the revolving workpiece and represents the resistance to the rotation of the workpiece In a normal operation, the tangential force is the highest of the three forces and accounts for about 98% of the total power required by the operation Longitudinal Force This acts in a direction parallel to the axis of the work piece and represents the resistance to the longitudinal feed of the tool The longitudinal force is usually about 50% as great as the tangential force As the feed velocity is usually very low in relation to the velocity of the rotating workpiece, the longitudinal force accounts for only about 1% of the total power required
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