Mechanics of Metal cutting & Chip Formation:- In metal cutting the metal is first compressed at the Cutting fluid

utting fluid is sometime also known as fubricants or coolants which may be solid liquid or gas Machinability:-* The case with which a given material may be cut so that the excess metal can be
area in front of the cutting edge duc which elastic deformation takes place after that plastic which is applied to the tool & workpiece (at cutting zone) to assist in the cutting operation. remove & gives a good surface finish at low cost. *Material having a good machinability require little
deformation ocuurs & when the stress in the work piece in front of cutting tool edge reaches a value characteristics of cutting fluid (a To cool the cutting tool & the workpiece (b. To lubricate the chip & power to cut, can be cut quickly, easily obtain a good finish & do not wear the tool much.
greater than ultimate strength of material, particle will shear to form a chip element which moves tool interface to reduce friction. (c To help carry away the chip. (d. To protect the finisher surface Machinability Index :-The machinability is not a basic standard but is a relative standard. This means
up along the face of tool. The plane along which metal shear is called shear plane thus the chip is from corrosion. application of cutting fluid.1 It Should have high heat absorption capacity2. It that to distingush to rate the machinability of a metal we have to tell it in relation to other metal by
formed by the plastic deformation of the metal structure along the shear plane. Tool Life* Tool life Should have high flash point so as to reduce chance of catching five at high temp3. It should not be using machinability index * Machinability index is defined as the percentage based on the relative
represents the useful life of the tool generally expressed in time units from the start o cut to an end reactive with work material4. It should be non-toxic for human.5 It should be orderless even at hig ease of machining a material for 20 minute tool life with respect to free cutting mild steel which is
point or failure point or regrinding. Tool life can be specified by any of the following measurable temperature.6. It should not corrode the work material.7. It should have low viscosity.8. It should be 100 percent & taken as the standard for 20 minute tool life. Factor which effect machinability 1.
quantity (a. Actual cutting time to failure. (b Length of work cut before failure (c. Volume of cheap.9. It should be trans parent so that cutting action of tool may be visible. Types of Chip :-There Chemical Composition of material 2. Micro structure of material 3. Mechanical Properties of
material removed to failure (d. Number of component produced before failure (e. Cutting speed for are three general types of chip which is formed while machining a metal1. Discontinuous Chip or Material 4. Physical Properties of Material. The characteristics of a cutting tool materials 1. High
a given time of failure Tool Life equation *Tool life of a cutting tool may be calculated by using the segnemtal form chip2. Continuous chip or Ribbon type chip3. Continuous chip with built-up-edge.1. Hardness:- The cutting tool material must have high hardness then the material to be machined so
following relation VT = C This equation is known as tailor tool equation where, V=Cutting Speed Discontinuous Chip:- When brittle material like cast iron are cut, the material fracture *This type of that it can penerate into the workpiece 2. Hot Hardness :-The cutting tool material must retain its
in m/minn. T=tool life in minute C= Constant (Numerically equal to the tool life for 1 minute) chip produce better surface finish, required low power & have good tool life *It can also form with hardness at elevated temperature so that it remain hard while working when temperature increase
n=Constant (tool, work material, surface finish) Orthogonal Cutting* In this method of cutting the some ductile material when cutting a very low speed and if cofficient of friction is low but the due to friction 3. Wear Resistance:- The cutting tool material must have high resistance to wear so
cutting edge is perpendicular to the direction of tool travel. *The direction of chip flow in surface finish is bad & tool life is short. *Condition which promote the formation of discontinuous that due to chip tool interface wear will be minimize. 4. Toughness:- The material should have
perpendicular to the cutting edge. *Only two component of the cutting force act on the tool. chip are:-1. Brittle Metal4. Small rake angle2. Greater depth of cut3. Low cutting Speed. 2. sufficient toughness to withstand shocks & vibrations generated during machining & prevent tool. 5.
Oblique Cutting* In this method of cutting the cutting edge of the tool is iclined to the direction of Continuous Chip :-Continous chips are normaly produced when machining steel or ductile metal at Low friction: The coefficient of friction between the tool and chip should be low so that less wea and
tool travel. *The direction of chip flow is inclined to the cutting edge. *Three component of the high cutting spec The chip is like a ribbon and flows along the rack face of the tool *It is the most heat generation will occur. 6. Thermal Conductivity:- Tool material should have high thermal
cutting force act on the tool. Flank Wear :- Wearing on the flat portion of the flank behind the desirable form of chip for low friction at tool-chip interface , lower power consumption, long tool life conductivity so that the heat generated during machining will be easily dissipated 7.Cost: The Tool
cutting edge due to which some clearance or relief is eliminated is known as flank wear. The worn & good surface finish. *Factor favourable to the formation of continuous chip are:-1. Ductile Metal2. material should have low cost.
region at the flank is called wear land. The width of wear land is measured accurately with a brinel Fine feed3. High cutting speed4. Large Rake angle 3. Continuous chip with built up edge :-This type
microscope. It generally ocurrs while machining brittle material. of chip is produce when there is building up of rigid metal on the top surface of the took above the
cutting edge. *The piled up metal formed on the top surface of the tool is the false cutting edge
which is known as "built up edge".

Tool geometry of single point cutting tool The elements which define the shape of a single point Pilots:- The pilots enables the correct location of the blank when it is fed by mechanical means. The Types of cutting tool Material
cutting tool are as follows:- a. Shank* Shank is that portion of the tool which is not grinded to form pilot enters unto the previously punched holes & move the metal sheet to the correct position until Ceramics:- *Ceramics are essentially alumina (aluminium oxide) based high refactory material. *It is
any cutting edge & is rectangular in cross section. b. Face Face of the cutting tool is that surface the stop engages. The pilot are fitted to the punch holders. Pressure Pad:-The pressure pad is made by compacting aluminium oxide powder in a mould & then sintered at 2200 degree celcius
against which the chip slides upwards. c. Flank Flank of a cutting tool is that surface which face the extremely important during a drawing operation. It is used to apply necessary holding force against which is known as cold pressing. *It is made in the form of tips that are clamped on metal shank &
work piece. d. Heel* It is the lowest portion of the bottom of the tool where the base & flank meet. the metal sheet so that uniform plastic deformation takes place during drawing operation. It have very low heat conductivity & extremly high compressive strength, resistance to carter wear,
e. Nose* The point where the side & end cutting edge meet is called the nose of the tool. f. Base eliminate wrinkling defects A pressure pad is shown in figure below As the punch moves downward abrasive wear & low friction of Co-efficient. *Ceramic tool can retain cutting edge hardness up to
The base of the tool is the under side of the shank. g. Rake* It is the slope of the top towards the she pressure pads which is a plate actuated by spring tension apply sufficient pressure on the metal 1400 degree celcius because of which it is used for higher cutting speed as compare to other tool
shank. h. Rake Angle* It is the angle formed between the face of the tool & a plane parallel to its sheet as it plastically flow between the punch & the. Misfeed Detector:- A mis feed detector is used material.*The main problem of ceramic tool is their brittlness & tendency of chipping due to which it
base. Drill* Drill is a fluted cutting tool used to originate or enlarge a hole in a solid material. in a way similar to that of pilot which detect the out of position of the sheet metal & the us actuate a is not used for interrupted cuts & for removing heavy chip. Cemented Carbide:- Cemented carbide
Tool Geometry of Drill It consist of following elements:- 1. Axis:- The longitudnal centre line of the switch which cut off the electric power to the press. * A misfeed detector system in shown below. It is invented around 1926 in germany & is the largest percentage of cutting tool used in metal cutting
drill is its axis.2. Body :-It is the portion of the drill from its extreme point to the start of the neck.3. consist of a detection pin & a relation pin whose one end is attached to the micro switch while other production.* Cemented carbide is produce through cold-compaction of WC powder in a binder of
Body Clearance:- It is that portion of body surface which is reduced in diameter to provide end rest on a groove cuted in detection pin when the punch decended && the sheet metal is food to cobalt followed by liquid phase sintering.* The carbide tool can retain there hardness up to 1000
clearance.4. Chisel Edge:- It is the edge formed by the intersection of the two flanks. It is also known its correct position then the detection pin enter directly into the previously punched hole on sheet degree celcius & have high wear resistance due to which it can operate at a cutting speed 3 to 6
as dead centre.5. Face:- The portion of the flute surface on which chips slide is known as face.6. metal & punch is performed but when the sheet metal is not in its correct position the detection pin times (about 5 to 6m/s of HSS). High speed Steel* High speed steel is the general purpose tool
Flute :-The groove in the body of the drill is known as flute. 7.The function of flute are:-1. To form moves up as the punch decended & thus the relation pin moves out & close the micro switch which material for lot and medium cutting speed due to its superior hot hardness & resistance to wear.*
the cutting edges on the point.2. To allow the chip to escape3. To make chip curl.4. To allow cutting turn off the press. Stops:-The stops are used for correct spacing of the sheet metal as it is fed below High speed steel operates at cutting speed 2-3 times higher than of carbon steel and retain there
fluid to reach the cutting edge8. Heel:- The edge formed by the intersection of the flute surface & the punch to give the maximum output in a given length of the plate* The common types of stops hardness upto about 900 dgree celcius. *Hot Hardness is due to alloying elements like tungstun,
body clearance 9. Lands :-The cylindrical surface on the leading edge of the drill flute10. Lip:- The are (a. Button Stop :-* The button stop is the simplest form of stop. lt is a small pin or a button fixed molybedenum, vanadium and chromium which form carbides. Diamond* Diamond due to its high
edge formed by the intersection of the flank & face11. Neck* The diameterically undercut portion to a die block at a measured distance from the punch axis. This make accurate spacing. It is used in hardness & chemically inert is ideal for obtaining fine surface finish & accuracy.* Diamond can take
between the body & the shank of the drill hand press & slow acting press. (b Lever Stop :-The lever stop is shown in figure above is operated high polish due to which chip do not adhere to its surface.* Diamond cutting edge is extremly
by the machine* The pin attached to the ram pushes the lever which lift the lever stop, leaving the smooth & completely free from surface irregularities & hence used for precision application.*
blank free then the plate is pushed aside immediately when the punch starts moving in the upward Diamond tool materials are either polycrystalline or single crystal in nature. PCD is the most popular
stroke & in the next stroke the lever is released from pin pressure & thus engage the stop & thus form of diamond tool & form directly over a tungsten carbide backing.
make an accurate spacing.
Properties of cutting fluid. :- It Should have high heat absorption capacity2.It should not be reactive Types of cutting tool Material* The selection of proper tool material depends on the types of Element of Reamer :- 1. Axis* The longitudnal centre line of the reamer is known as its axis.2. Back
with work material.3. It should be non-toxic for human.4. It should be orderless even at hig material and method of machining required. The principle cutting material are:-1. Carbon Steel* taper* The reduction in a diameter per 100mm length of the reamer from entering end towards
temperature.5. It should not corrode the work material.6. It should have low viscosity.7. It should be These are plain carbon steel with steel with no appropriate alloying element added to it. A very shank.3. Body* The portion of the reamer extending from the entering end of the reamer to the
cheap. small amount of silicon, magnese, chromium or vanadium is present to increase hardness. The commencement of its shank.4. Circular land* The cylindrically ground surface adjacent to the
Types of cutting fluid 1. Soluble oils* Soluble oils are emulsions composed of 80% water, soap & carbon content varies from 0.6 to 1.5%.* The major disadvantage of this tool material is that it cutting edge, on the leading edge of the land.5. Cutting edge* The edge formed by the intersection
mineral oil soap act as emulsifying agent &break the oil so that it will get mixed with water evenly.* looses its hardness beyond 200degree Celcius and unable to cut and are usefull only for very low of the face & the circular land is called cutting edge.6. Face* The portion of the flute surface on
The water increase the cooling effect while the oil reduce friction & protect metal from corrosion. cutting speed upto 0.15m/s and with low temperature operation. which chip slides while cutting operation is called face.7. Flute* The groove in the body of the
2.Chemical compound.* This type of cutting fluid consist of rust inhibitor such as sodium nitrate, The different punch& de mounting are :- Pilots :-* The pilots enables the correct location of the reamer to provide space for chip to move upward & allow cutting fluid to reach the cutting edge.8.
mixed with high percentage of water.3. Solid lubricant.* Stick waxes &bar soap are some-times blank when it is fed by mechanical means.* The pilot enters into the previously punched holes & Recess* The portion of the body which is reduced in diameter is known as recess.9. Shank:-The
used as lubricant to the cutting tool where cutting speed is very low.4. Water* Water, plain or alkali move the metal sheet to the correct position until the stop engages. The pilot are fitted to the punch portion of the reamer by which it is held & driven is known as shank.10. Primary clearance angle*
or water soluble additives are used sometime as a coolant. But it produce a risk of corrosiveness of holders. Strippers * Stripper is used to remove the metal sheet from the punch after a blanking or The angle between the circular land & the line tangent to the cutting edge is called primary
work material. piercing (punching) operation & also prevent the metal sheet from distortion.* There are two types clearance angle11. Secondary clearance angle* The angle formed by the secondary clearance & the
Shear angle* Shear angle is defined as the angle between the shear plane with the direction of tool of strippers a. Channel-type fixed strippers b. Spring operated strippers. Knockouts :- The knockout line drawn tangent to the cutting edge is called secondary clearance angle.
travel. Flank Wear (Abrasive/Adhesive Process)* Wearing on the flat portion of the flank behind the is also a type of stripper which forces the finish/scrap component out of the die.* A knockout fitted Injection Moulding :-* Injection moulding is the process of creating a plastic component by forcing
cutting edge due to which some clearance or relief is eliminated is known as flank wear.* The worn on a inverted blanking die is shown in figure below. As the die decents, the metal sheet is cutted & the melted plastic into a die cavity. * Provision for over flow is provided which ensure complete
region at the flank is called wear land.*The width of wear land is measured accurately with a brinel the blank rests on the knockout plate in depression due to the spring compression. As the die moves filling of the die cavity.* A locating ring is provided at the center of the die which allow injector to
microscope.* It generally ocurrs while machining brittle material. Rake angle* It is the angle in upward stroke, the knockout plate ejects the scrap out of the punch. Pressure Pad* The pressure complete. lt fit with thesprue.* Sprue helps to distribute the liquid plastic into the die cavity.* For
between the face of the tool, called the rack face & the normal to the machining direction. pad is extremely important during a drawing operation. It is used to apply necessary holding force fast cooling of the die a water line is provided inside the both half of die. Metal Extrusion Die:-*
Clearance angle:-It is the angle between the machined surface & the underside of the tool called the against the metal sheet so that uniform plastic deformation takes place during drawing operation. It Extrusion is the process used to create objects of a fixed cross-section by pushing material through a
flank face. Lip angle/Cutting angle/Knife angle Wedge angle* It is defined as the angle between the eliminate wrinkling defects.* A pressure pad is shown in figure below. As the punch moves die of the desired cross section. *A extrusion die consist of a feeder plate, die ring, die holder, a die,
tool rack face & flank face. downwards the pressure pads which is a plate actuated by spring tension apply sufficient pressure a backer plate, a bolster plate & a die slide.* The die ring/die holder hold the die & the feeder plate
on the metal sheet as it plastically flow between the punch & the die during drawing operation. & the die backe together.

Compound Die :-In a compound die two or more cutting operations are performed at one station of Punching:- *Punching is the operation of producing a cylindrical (circular) hole in a sheet metal by Curling* The curling is the operation of forming the edge of a component into a roll or a curl by
the press in every stroke of a ram. * In the above figure, the blanking die & the piercing punch are the punch & die. *The material punched out is the waste while the metal sheet on which hole is bending the sheet metal.* It is done to strengthen the edge & to provide smoothness to it surface.*
bolted to the ram. The stripper plate is spring loaded inside the blanking die. The lower body has produce is the desired component. *The size of the hole is determine by the size of the punch & The curling operation is shown in figure as the punch decends into the die the metal roll into a curl
cutting edge both on its outward & inward surface. The outward cutting edge serves as a punch for clearance is allowed on the die. Blanking:- Blanking is the operation of cutting out different shapes in the radiused cavity of the punch.* Sometime the curling of the edge are made over a wire to add
blanking operation & the inside cutting edge operates as a die for the piercing punch. Combination from a flat metal sheet. *The metal which is punched out is the required product, while the sheet is strength to the edge. stamping* Stamping is a low cost high speed manufacturing process that can
Die:- In a combination die, both cutting & non-cutting operation are accomplished at one station of the waste material. *In blanking the size of the blank is governed by the size of the die while produce a high volume of identical metal components.* Stamping involves many metal forming
the press in every stroke of the ram.*The figure below shows a combination of blanking & drawing clearance is provided on the punch.. Strip Layout* To decide the position of the workpiece in the process like punching, blanking, bending, coining on a single machine to achieve the desired shape..
die, showing two stages of the operation. *The upper block serve as blanking punch & also contain a strip & their orientation with respect to one another is called strip layout.* Strip layout gives an idea Notching:- Notching is the operation of removal of the material to the desired shape from the edge
drawing punch inside it as its center. As the punch moves downward the metal first sheared & the on the position of various punches, stops & pilots to be placed • A good strip layout help to reduce of the metal plate. *The part cutted out is the scrap while the metal plate is the usefull components.
required size of the blank is obtained then the inner punch moves downward & draws out the metal the waste & help in better utilization of raw material (Stock).A strip layout is good or bad is decided Lancing* Lancing is the operation of cutting a sheet metal through part of its length & then bend the
in the desired cup shape, while the blanking punch serve as pressure plate. Simple Die :-It is also by material utilization factor. Clearance in Punching:-* The punching operation the hole generated cutted portion at desired angle. Embossing:-* Embossing is the operation used in making raised
known as single operation die.*In a simple die only one operation is performed at each stroke of the has to be in accurate size & the slug is to be discarded so to attain the accurate size of hole the figures on metal sheets with its corresponding relief on the other side.* The process involves
ram. It consist of die block & stripper plate which holds the metal sheet when the punch performe punch is made to the size & the clearance is provided on the die. Clearance in blanking:-In blanking drawing & bending of the metal. *An example of embossing operation is shown in figure, the die set
the cutting operation. *It is usefull for manufacturing simple metal parts in smaller quantities. operation the blank (slug) generated has to be in accurate size so to attain the accurate size of the contain the desired contours so that when the punch meet, the clearance between them is equal to
Progressive Die :-In a progressive die two or more operation are performed simultaneously at a blank the hole in the die is made to the size de the clearance is provided on the punch. the sheet thickness. *Embossing is used for providing dimples on sheets to increase rigidity & for
single stroke of the press by mounting separate sets of die & punches at two or more different decorative sheet work used for panels in houses & religious places. Coining:- The coming is the
station. The metal sheet is progressed from one station to other till the complete part is obtained.* operation of producing coins or other ornamental parts by squeezing operation. *In this process the
The progressive punching & the blanking die is shown in figure below. The sheet metal is feed into metal having good plasticity & of proper size is placed within the punch & the die & tremendous
the first die where a hole is pierced by the piercing die set & in the first cutting stroke of ram. The pressure is applied from both ends, thus under severe compressive load, the metal at top surface
plate is then move in the next station & in the second stroke of the ram the punch shear the plate to flows in the cold state & fills the cavity of the punch & die.* The component thus produce gets a
form washer. By the time the blanking operation is performed the hole for the next washer is also sharp impression on its two sides, corresponding to the engravings on the punch & the die
pierced at the first station.