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Material-Removal Processes: Cutting: Manufacturing Processes For Engineering Materials, 4th Ed
Material-Removal Processes: Cutting: Manufacturing Processes For Engineering Materials, 4th Ed
Material-
Removal
Processes:
Cutting
FIGURE 8.3 (a) Schematic illustration of the basic mechanism of chip formation in cutting.
(b) Velocity diagram in the cutting zone.
FIGURE 8.5 Shiny (burnished) surface on the tool side of a continuous chip produced in
turning.
FIGURE 8.8 Various chips produced in turning: (a) tightly curled chip; (b) chip hits workpiece
and breaks; (c) continuous chip moving away from workpiece; and (d) chip hits tool shank and
breaks off. Source: G. Boothroyd, Fundamentals of Metal Machining and Machine Tools.
FIGURE 8.9 (a) Schematic illustration of cutting with an oblique tool. (b) Top view,
showing the inclination angle i. (c) Types of chips produced with different inclination angles.
FIGURE 8.10 (a) Schematic illustration of a right-hand cutting tool. Although these tools
have traditionally been produced from solid tool-steel bars, they have been largely replaced
by carbide or other inserts of various shapes and sizes, as shown in (b).
FIGURE 8.21 (a) Crater wear and (b) flank wear on a carbide tool. Source: J. C, Keefe,
Lehigh University.
FIGURE 8.33 Relative edge strength and tendency for chipping and breaking of inserts
with various shapes. Strength refers to that of the cutting edge shown by the included angles.
Source: Kennametal, Inc.
FIGURE 8.38 Ranges of properties for various groups of tool materials. (See also various
tables in this chapter.)
FIGURE 8.41 (a) Designations and symbols for a right-hand cutting tool; solid high-speed-steel
tools have a similar designation. The designation “right hand” means that the tool travels from right
to left, as shown in Fig. 8.19 (b) Square insert in a right-hand toolholder for a turning operation. A
wide variety of toolholder is available for holding inserts at various angles. Thus, the angles shown
in (a) can be achieved easily by selecting an appropriate insert and toolholder. Source: Kennametal,
Inc.
FIGURE 8.42 (a) Schematic illustration of a turning operation showing depth of cut, d, and feed, f. cutting speed is the surface
speed of the workpiece at the tool tip. (b) Forces acting on a cutting tool in turning. Fc is the cutting force; Ft is the thrust or feed
force (in the direction of feed); and Fr is the radial force that tends to push the tool away from the workpiece being machined.
Compare this figure with Fig. 8.11 for a two-dimensional cutting operation.
FIGURE 8.43 The range of applicable cutting speeds and fees for a variety of tool
materials. Source: Valenite, Inc.
Note: (a) These speeds are for carbides and ceramic cutting tools. Speeds for high-speed steel
tool are lower than indicated. The higher ranges are for coated carbides and cermets. Speeds for
diamond tools are significantly higher than those indicated.
(b) Depths of cut, d, are generally in the range of 0.5-12 mm (0.02-0.5 in.)
(c) Feeds, f, are generally in the range of 0.15-1 mm/rev (0.006-0.040 in./rev).
TABLE 8.8 Approximate range of recommended cutting speeds for turning operations.
FIGURE 8.48 (a) Standard chisel-point drill, with various features indicated. (b)
Crankshaft-point drill.
Note: As hole depth increases, speeds and feeds should be reduced. Selection of speeds and
feeds also depends on the specific surface finish required.
FIGURE 8.53 (a) Schematic illustration of conventional milling and climb milling. (b) Slab-
milling operation, showing depth of cut, d; feed per tooth, f; chip depth of cut, tc; and workpiece
speed, v. (c) Schematic illustration of cutter travel distance to reach full depth of cut.