Heat in metal cutting
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This presentation gives details on Heat Generation in Metal Cutting tool. There are three zones of heat generation where heat generation equation is also derived by analytical method.
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heat in metal cutting
The document discusses heat generation and temperature measurement in metal cutting. It states that the bulk of the power consumed in metal cutting is converted to heat near the tool-chip interface, with temperatures potentially reaching 6000C. It then describes several methods to measure cutting temperatures, including calorimetry, thermocouples, embedded thermocouples, photo-cell techniques, and infrared photography. The last method allows mapping temperature distributions at tool-chip and tool-workpiece interfaces.
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Thermal aspects in machining
- The document discusses heat generation in machining and its effects, temperature measurement techniques, types and functions of cutting fluids, and economics of metal cutting operations.
- Heat is generated in three zones during machining: the primary deformation zone, tool-chip interface, and tool-workpiece interface. Heat depends on factors like material properties and cutting parameters.
- High temperatures can damage tools and workpieces. Cutting fluids help reduce temperatures by conduction and convection of heat away from the cutting zone.
- Temperature is commonly measured using tool-workpiece thermocouples, which generate electrical signals related to temperature at the cutting interface.
4 types of chips (1)
1. Chips are formed during machining when excess metal is sheared off the workpiece. There are three main types of chips: discontinuous, continuous, and continuous with built-up edge.
2. Discontinuous chips form with brittle materials while continuous chips form with ductile materials at high speeds. Continuous chips with built-up edge form with friction at low-medium speeds.
3. Chip breakers are used to break long continuous chips for safety and chip disposal. Built-up edges form from friction but can be prevented by reducing friction, pressure, temperature through rake angle, lubrication and speed/feed adjustments.
Orthogonal & oblique cutting
Metal cutting involves removing unwanted material from a workpiece. In orthogonal cutting, the cutting tool edge is perpendicular to the direction of motion, so chip flow is perpendicular to the cutting edge. In oblique cutting, the cutting tool edge is at an angle to the direction of motion, so chip flow is sideways. Orthogonal cutting results in higher heat concentration, shorter tool life, and poorer surface finish than oblique cutting. Oblique cutting is used for most industrial processes like drilling and milling.
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Theory of Metal Cutting
The document discusses machining processes and cutting tools. It provides definitions of machining and cutting tools. It describes:
- The importance of machining processes in manufacturing precise parts.
- Objectives of machining like high material removal rate and surface finish, low tool and power costs.
- Classification of cutting tools based on how relative motion is provided between tool and workpiece.
- Key terms related to cutting tool geometry like rake angle, relief angle, and their influence on tool strength and chip removal.
- Mechanism of chip formation and different types of chips produced.
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This document provides information on machining processes and machine tools. It discusses machine tools and their functions in machining operations like holding the workpiece, positioning the tool, and providing power. It also covers the mechanics of machining, important machining parameters like chip thickness and rake angle. It explains the mechanism of chip formation, shear angle, shear strain, and velocity diagrams. It discusses different types of chips and provides information on cutting forces, temperatures generated during machining, and classification of cutting tools.
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heat in metal cutting
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Thermal aspects in machining
- The document discusses heat generation in machining and its effects, temperature measurement techniques, types and functions of cutting fluids, and economics of metal cutting operations.
- Heat is generated in three zones during machining: the primary deformation zone, tool-chip interface, and tool-workpiece interface. Heat depends on factors like material properties and cutting parameters.
- High temperatures can damage tools and workpieces. Cutting fluids help reduce temperatures by conduction and convection of heat away from the cutting zone.
- Temperature is commonly measured using tool-workpiece thermocouples, which generate electrical signals related to temperature at the cutting interface.
4 types of chips (1)
1. Chips are formed during machining when excess metal is sheared off the workpiece. There are three main types of chips: discontinuous, continuous, and continuous with built-up edge.
2. Discontinuous chips form with brittle materials while continuous chips form with ductile materials at high speeds. Continuous chips with built-up edge form with friction at low-medium speeds.
3. Chip breakers are used to break long continuous chips for safety and chip disposal. Built-up edges form from friction but can be prevented by reducing friction, pressure, temperature through rake angle, lubrication and speed/feed adjustments.
Orthogonal & oblique cutting
Metal cutting involves removing unwanted material from a workpiece. In orthogonal cutting, the cutting tool edge is perpendicular to the direction of motion, so chip flow is perpendicular to the cutting edge. In oblique cutting, the cutting tool edge is at an angle to the direction of motion, so chip flow is sideways. Orthogonal cutting results in higher heat concentration, shorter tool life, and poorer surface finish than oblique cutting. Oblique cutting is used for most industrial processes like drilling and milling.
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this presentation tries to explain the various heat zones that are developed during the metal cutting process. furthermore, how much heat is dissipated from the various zones. lastly the possible methods of temperature reduction in brief.
Theory of Metal Cutting
The document discusses machining processes and cutting tools. It provides definitions of machining and cutting tools. It describes:
- The importance of machining processes in manufacturing precise parts.
- Objectives of machining like high material removal rate and surface finish, low tool and power costs.
- Classification of cutting tools based on how relative motion is provided between tool and workpiece.
- Key terms related to cutting tool geometry like rake angle, relief angle, and their influence on tool strength and chip removal.
- Mechanism of chip formation and different types of chips produced.
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This document provides information on machining processes and machine tools. It discusses machine tools and their functions in machining operations like holding the workpiece, positioning the tool, and providing power. It also covers the mechanics of machining, important machining parameters like chip thickness and rake angle. It explains the mechanism of chip formation, shear angle, shear strain, and velocity diagrams. It discusses different types of chips and provides information on cutting forces, temperatures generated during machining, and classification of cutting tools.
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Tool wear and failure can occur through three modes: fracture, temperature failure, or gradual wear. Gradual wear is preferred as it leads to the longest tool life. Wear occurs primarily at the rake face (crater wear) and flank face (flank wear) through mechanisms such as abrasion, adhesion, diffusion, chemical reactions, and plastic deformation. Tool life is defined as the cutting time until a certain wear criteria is reached, such as 0.5mm flank wear. The Taylor tool life equation describes the relationship between cutting speed, tool life, and material properties.
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Tool life is measured by the time period from when a tool starts cutting until failure or until it needs resharpening. Tool life can be measured in units of time, number of pieces cut, volume of material removed, or length of cut. Tools typically fail due to high temperatures, mechanical impacts, or gradual wear. Wear occurs on the flank and crater faces of tools and is caused by abrasion, diffusion, electrochemical reactions, and other mechanisms. Factors like cutting speed, workpiece properties, tool geometry, and cooling influence tool life.
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Hot and cold working
1. Cold working is the plastic deformation of metals at a temperature below the recrystallization temperature, while hot working occurs above the recrystallization temperature.
2. Metal spinning is a metalworking process that forms an axially symmetric part by rotating a disc or tube of metal at high speed against a spinning roller. It can be done by hand or CNC lathe.
3. Forging processes like upsetting, heading, blocking, and fullering are used to refine the shape of metals for finishing. Punching and blanking are shearing processes used to produce holes.
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1. The document discusses the theory of metal cutting, including mechanics of chip formation, types of chips, cutting tool materials, tool wear, and other related topics.
2. It describes the different types of tool wear that can occur, including flank wear which results from the gradual wearing away of the cutting edge, and crater wear.
3. The key factors that influence chip formation and tool wear are also examined, such as material properties, cutting conditions, tool geometry, and choice of cutting tool material.
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The document discusses cutting tools and their properties. It describes different types of cutting tool materials like high-speed steel, cemented carbides, ceramics, and diamond. It explains cutting tool nomenclature and defines terms like rake angle, clearance angle, nose, and flank. It also discusses factors that affect tool life like cutting conditions, work material properties, and tool material.
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2. Common forming operations include bending, drawing, stamping, spinning, and stretching. Cutting operations include blanking, punching, and shearing.
3. Bending involves curving sheet metal between a punch and die. Drawing uses a punch to force sheet metal into a die cavity. Stretch forming stresses sheet metal beyond its elastic limit with a forming block.
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1. The document discusses thermal aspects of machining including cutting temperatures, tool materials, tool wear, and cutting fluids.
2. Cutting temperatures can reach up to 6000C at the tool-chip interface and have a controlling influence on tool wear and friction.
3. High cutting temperatures reduce tool life, pose safety hazards to hot chips, and can cause workpiece inaccuracies due to thermal expansion.
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Different tool materials and their applications including effect of tool coating
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Tool wear and failure can occur through three modes: fracture, temperature failure, or gradual wear. Gradual wear is preferred as it leads to the longest tool life. Wear occurs primarily at the rake face (crater wear) and flank face (flank wear) through mechanisms such as abrasion, adhesion, diffusion, chemical reactions, and plastic deformation. Tool life is defined as the cutting time until a certain wear criteria is reached, such as 0.5mm flank wear. The Taylor tool life equation describes the relationship between cutting speed, tool life, and material properties.
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1. Sheet metal forming operations include bending, stretching, deep drawing, and other processes where sheets are formed. Bending involves shaping a straight length into a curve and can be done using presses or rolls.
2. Deep drawing uses a die and punch to shape flat sheets into cup-shaped parts. Stretch forming clamps sheet edges and stretches the sheet over a die into the desired shape.
3. Successful forming requires considering the material properties, die and process parameters to avoid defects like cracks, wrinkles, and non-uniform thinning. Minimum bend radii, lubrication, and holding pressure all impact the quality of formed parts.
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In machining or metal cutting operation the device used for determination of cutting forces is known as a Tool Dynamometer or Force Dynamometer.
Hence, it is essential to study the metal cutting process for economical aspects of the manufacture of the components.
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This document discusses factors that affect tool life in machining processes. It identifies the main factors as cutting tool geometry, material, characteristics, cutting conditions, workpiece material, and cutting fluid. Cutting tool geometry influences machined surface quality, productivity, chip control, and forces/temperatures. Cutting tool material and coatings must have properties like heat/wear resistance. Cutting conditions like depth of cut, feed rate, and cutting speed also impact tool life. Workpiece material properties and machinability affect tool performance. Cutting fluids provide lubrication, cooling and chip removal to extend tool life. Environmental impacts of fluids are also considered.
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Tool life is measured by the time period from when a tool starts cutting until failure or until it needs resharpening. Tool life can be measured in units of time, number of pieces cut, volume of material removed, or length of cut. Tools typically fail due to high temperatures, mechanical impacts, or gradual wear. Wear occurs on the flank and crater faces of tools and is caused by abrasion, diffusion, electrochemical reactions, and other mechanisms. Factors like cutting speed, workpiece properties, tool geometry, and cooling influence tool life.
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This chapter aims to provide basic backgrounds of different types of machining processes and highlights on an understanding of important parameters which affects machining of metals with their chip removals.
Metal cutting or Machining is the process of producing workpiece by removing unwanted material from a block of metal. in the form of chips. This process is most important since almost all the products get their final shape and size by metal removal. either directly or indirectly.
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Dynamo meters are the electronic devices that are widely used to the purpose of force analysis in various field of operations. There is various types of dynamometers such as
Lathe tool dynamometer
Milling tool dynamometer
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The document provides information about tool wear and tool life in machining processes. It discusses how tool wear occurs due to forces, temperature, and sliding action during cutting. The three main types of tool wear are flank wear, crater wear, and chipping. Flank wear is caused by abrasion from hard particles in the workpiece while crater wear results from high temperatures and diffusion at the tool-chip interface. Maintaining optimal cutting conditions and tool geometry can increase tool life. The document also covers tool materials, machinability factors, cutting fluids, machining forces, and lathe operations such as turning, facing, and threading.
Hot and cold working
1. Cold working is the plastic deformation of metals at a temperature below the recrystallization temperature, while hot working occurs above the recrystallization temperature.
2. Metal spinning is a metalworking process that forms an axially symmetric part by rotating a disc or tube of metal at high speed against a spinning roller. It can be done by hand or CNC lathe.
3. Forging processes like upsetting, heading, blocking, and fullering are used to refine the shape of metals for finishing. Punching and blanking are shearing processes used to produce holes.
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1. The document discusses the theory of metal cutting, including mechanics of chip formation, types of chips, cutting tool materials, tool wear, and other related topics.
2. It describes the different types of tool wear that can occur, including flank wear which results from the gradual wearing away of the cutting edge, and crater wear.
3. The key factors that influence chip formation and tool wear are also examined, such as material properties, cutting conditions, tool geometry, and choice of cutting tool material.
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The document discusses cutting tools and their properties. It describes different types of cutting tool materials like high-speed steel, cemented carbides, ceramics, and diamond. It explains cutting tool nomenclature and defines terms like rake angle, clearance angle, nose, and flank. It also discusses factors that affect tool life like cutting conditions, work material properties, and tool material.
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1. Sheet metal work involves forming metal sheets 3-5mm thick into parts through cutting, forming, and joining processes.
2. Common forming operations include bending, drawing, stamping, spinning, and stretching. Cutting operations include blanking, punching, and shearing.
3. Bending involves curving sheet metal between a punch and die. Drawing uses a punch to force sheet metal into a die cavity. Stretch forming stresses sheet metal beyond its elastic limit with a forming block.
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Heat in metal cutting
- 1. By Amit Sonchhatra (11BM081) Athar Kothawala (11BM082) Karan C. Prajapati (11BM083) Yudhishthir Ramnani (11BM084) Samiraj Anupam (11BM085) 1 Heat in Metal Cutting School of Technology Knowledge Corridor, Raisan, Gandhinagar- 382007,Gujarat
- 2. Introduction 2 90 to 100 % of Mechanical Energy is converted into Thermal Energy. Hence, Temperature is of major concern. The mechanical process and the thermal dynamic process are tightly coupled together. Cutting temperatures strongly influence tool wear, tool life, workpiece surface integrity, chip formation mechanism and contribute to the thermal deformation of the cutting tool.
- 3. Heat Dissipation in metal cutting 3
- 5. 5
- 6. Or workpiece against the flank surface of the tool 3 Sources of Heat Generation 6
- 7. 7 1. Primary Source: Plastic Deformation in shear plane and viscous dissipation (Primary Zone)
- 8. 8
- 9. chip on the rake surface of tool. (Secondary Zone) 9
- 10. Heat Generated in Tertiary Zone 10
- 11. Effect of Cutting Speed on Temperature Distribution 11
- 12. Temperature Distribution in Metal Cutting 12
- 13. Contd. 13
- 14. High Temperature Effect on Tool 14 Reduces strength of the tool and formation of create wear. Shortens tool life Causes thermal distortion Causes dimensional change in work piece Temperature on metal cutting and cutting fluids, making of control dimensional accuracy difficult
- 15. Temperature Control in Metal Cutting 15 Application of Cutting Fluid (coolant). Changing the cutting condition by reduction of cutting speed and/or feed. Selection of proper cutting Geometry.
- 16. Cutting Fluid Properties Functions 16 High thermal conductivity and specific heat. Odorless Non-Corrosive to work and machine. Non-toxic to operating worker. Low Viscosity Lubrication Reduction of cutting force and energy. Cooling Improve surface finish
- 17. Types of Cutting Fluid 17 Cutting Fluids Oil based Chlorinated oil Mineral oil Fatty Oils Soluble oil Sulphurised oil Water based
- 18. Effect of Cutting Fluid 18
- 19. Contd. 19
- 20. Factors 20 Cutting conditions Material Cost of cutting fluid • V • F • d • Cutting tool • Work Material
- 21. Factors based on application 21
- 22. Application 22
- 23. Effect of Cutting Fluid in tool life 23
- 24. Effect of cutting fluid in cutting speed 24
- 25. To find value of Pp and Ps, Merchant Circle Force Analysis is done which is done in subsequent slides 25
- 26. Assumptions of Merchant Circle Force Analysis 26
- 27. Diagram of Merchant Circle 27
- 28. 28 It is Fs Here F=Frictional Force=Ff
- 29. 29
- 30. 30
- 31. 31 • Pp= Fs*Vs Where Fs=Force in shear plane and Vs=Shear velocity • Ps=Ff*Vc Where Ff=Frictional Force=Ff and Vc=Chip Velocity
- 32. Reference 32 http://www.mfg.mtu.edu/marc/primers/heat/heat.h tml http://me.emu.edu.tr/me364/ME364_cutting_temp eratures.pdf http://nathbeke.files.wordpress.com/2013/01/l4- temprature-and-cooling.pdf Investigation of heat partition in high speed turning of high strength alloy steel Production Technology by Hindustan Machine Tool Metal Cutting and Machine Tools by P N Rao
- 33. Thank You 33