Theory of Metal Cutting
Theory of Metal Cutting
SEM.IV
Prepared by
PROF.SUDHAKAR S. AMBHORE
Date: 05.02.2019
MODULE.1
METAL CUTTING
1.1 Introduction:
Metal cutting process forms the basis of engineering industry & is involved either
directly or indirectly in the manufacture of nearly every product of our modern civilization. The
theory of metal cutting is of vital importance and a basic knowledge of fundamentals of
machining of materials and of the theory of metal cutting will help to develop scientific approach
in solving problems encountered in machining.
A metal cutting tool is the part of a metal cutting machine tool that, in the cutting process,
acts directly on the blank from which the finished part is to be made. The metal cutting process
accompanied by deformation in compression, tension & shear by a great deal of friction & heat
generation is governed by definite laws. Metal cutting operation involves three basic
requirements. (1) There must be a cutting tool that is harder and wear resistant than the work
piece material, (2) there must be interference between the tool & the work piece as designated by
the feed and depth of cut, and (3) There must be relative motion or cutting velocity between the
tool & the work piece with sufficient force and power to overcome the resistance of work piece
material. As long as above three conditions exist, the portion of the material being machined that
interferes with free passage of the tool will be displaced to create a chip.
1.2 Classification of production process:
The metals are given different usable forms by various processes. These processes may
be classified as under.
Metal Forming
In chip removal processes the desired shape and dimensions are obtained by separating a layer
from the parent work piece in the form of chips. During the process of metal cutting there is a
relative motion between the work piece & cutting tool. Such a relative motion is produced by a
combination of rotary and translatory movements either of the work piece or of cutting tool or of
both. These relative motions depend upon the type of metal cutting operation. The following
table indicates the nature of relative motion for various cutting processes.
Table 1.1
In chip less processes the metal is given the desired shape without removing any material
from the parent work piece.
1.4.1 Cutting Speed (V) – It is the travel of a point on cutting edge relative to surface of cut in
unit time in process of accomplishing the primary cutting motion. It is denoted by ‘V’. The unit
of cutting speed is m/min.
In lathe work for turning a blank of diameter ‘D’ mm, (The diameter of machined surface
is ‘Do’ mm.) rotating at a speed ‘N’ (rpm) the cutting speed at periphery (maximum) is given by.
V = π D N /1000, m/min ........………………………….. 1.41
SPEED
β K
M β N N
N P
P
L
Fig. 1.3 Force acting on an indenting wedge Fig. 1.4 Force triangle at the wedge check
. The body resists the motion of the wedge. The reactions N.N. appear at the cheeks of the
wedge. The forces N.N. are perpendicular to the cheeks in absence of friction. From the
equilibrium of forces (fig.1.4) The mechanical advantage on application of force P is given by
N KM 1 1
M. A. = = = =
P KL KL / 2 2 sin β
2
KM 2
Work surface
K
N
β
N P β
N L 900
α
P
Fig.1.5 Orientation of the wedge during the parting Fig.1.6 Orientation of the wedge
or cutting by the indentation process during the separation of chips
Thus, the mechanical advantage in force is dependent on the wedge angle 'B'. The smaller the
angle of wedge, the greater will be the gain in force. In other words, the wedge angle 'β'
determines the resisting force of the cutting edge.
The cutting edge must be oriented at certain required angles with the work surface
depending on nature of operation to be performed. Fig.1.5 shows that the wedge must be set at
right angles to the work surface, so that the driving force "P" is in the direction of parting.
During chipping the wedge must be set at an angle inclined to work surface so that separation of
chip can be done. (Fig.1.6)
Thus for the wedge two geometric parameters can be defined i.e. (1) The wedge angle 'β β'
and (2) the axis of symmetry along which 'P' acts. In addition to above, two more parameters
are introduced to confirm conditions of chipping action. These parameters are set with respect to
velocity Vector, 'V' and are defined as (3) cutting angle 'δδ' and (4) clearance angle'α;, as shown
in fig.1.6. The sign convention for describing these angles is set w.r.t. left handed cork screw
rule with "Z" axis coinciding with the direction of the velocity vector, V, and the cutting edge
lying along 'Y' axis. Hence, 'δ' & 'α' are measured positive, when moving from 'Z' to 'X' axis as
shown in fig.1.7. The parameter ' γ ' defines the inclination of the top face of the wedge (called
Rake face) w.r.t. velocity vector V, while the parameter 'α' describes the relief provided from the
bottom face of the wedge (called flank), often another derived parameter, called (5) Rake angle
'γγ', is used to describe the inclination of the top face of the wedge. This is derived parameter
given by γ = 900 - δ .
However if δ > 90, then ' γ ' is negative. Thus from this equation it may be seen that
while 'δ' is always positive the rake angle can become positive or negative depending on value of
angle 'δ'.
v
δ
δ
β
β
However in Fig.1.7 the cutting edge of the wedge has been set at right angle to velocity
vector, V, along Y-axis. A new situation arises when the cutting edge shifts from Y axis and
another parameter called (6) Inclination angle is needed to describe the orientation of the wedge
with respect to velocity vector "V". The angle " λ " is measured positive when it lies in the
direction or rotation of left hand cork crew rule in the x-y-z system as shown.
When wedge shaped tool is set w.r.t. the work-place the actual values of the rake angle 'ϒ' and
clearance angle 'α' depend on the actual direction of velocity vector V with respect to the wedge.
The effect of setting the wedge has been shown in fig.1.8. It the wedge is set high w.r.t. line of
centers, the rake angle increases to (Ψ+ ϒ) from ϒ & clearance angle decreases to ( α - Ψ ) from
'α' opposite is the case when wedge is set low.
V
Ψ+γ
α-Ψ
Fig19. Fig1.10
99
a b c d
1) Discontinuous Chips: These chips are in the form of small individual segments, which may
adhere loosely to each other to form a loose chip. These chips are formed as result of machining
of a brittle material such as gray cast iron or brass castings, etc. These chips are produced by
actual rupture or fracture of metal ahead of the tool in brittle manner. Since the chips break up
into small segments and also shorter chips have no interference with work surface. The friction
between chip & tool reduces resulting in better surface finish. These chips are convenient to
collect, handle & dispose off during production runs. The conditions favourable for formation of
discontinuous chips are:
1) Brittle & non ductile metals (like cast iron brass castings Beryllium, titanium etc.)
2) Low cutting speed.
3) Small rake angle of the tool.
4) Large chip thickness.
2) Continuous Chips: These chips are in the form of long coils having uniform thickness
throughout. These chips are formed as result of machining of relatively ductile materials where
definite successive raptures do not take place, at high cutting speeds. Due to large deformation
possible with ductile materials longer continuous chips are produced. These are referred to as
“ideal” chips because,
i) Due to stable cutting excellent surface finish is obtained.
ii) Low friction between chip & tool & hence heat generation is low and,
iii) Power consumption is low. On the other hand, these chips are difficult to handle & dispose
off. Chip coils can cause injury to operation. However these problems can be avoided by use of
“chip breakers” behind to cutting edge. The conditions favourable for formation of continuous
chips are
1) Ductile material
2) High cutting speeds.
3) Large rake angle of tool.
4) Small chip thickness.
5) Sharp cutting edge.
6) Efficient cutting fluid.
7) Low friction between chip tool interfaces.
3) BUE Chip (or continuous Chip with BUE): These chips are also produced in the form of
long coils like continuous chips, but they are not as smooth as continuous chips. These chips are
characterized by formation of built up edge on the nose of the tool owing to welding of chip
material on to tool face because of high friction between chip tool interfaces. Presence of this
welded material further increases the friction leading to building up of the edge, layer by layer.
As the built-up edge continuous to grow, the chip flow breaks a portion of it into fragments.
Some of them are deposited on the work piece material while the rest are carried away by the
chips. The hardness of this BUE is two to three times higher than the work piece material. This
is the reason why the cutting edge remains active even when it is covered with built-up edge.
The only point in favor of BUE is that it protects the cutting edge from wear due to moving chips
and the action of heat. This brings about an increase in tool life. These chips normally occur
while cutting ductile materials with HSS tools with low cutting speeds. Chips with BUE are
undesirable as they result in higher power consumption, poor surface finish and higher tool wear.
Generally speaking any change in cutting conditions that will eliminate or reduce BUE is
desirable, since high friction between chip & tool face is major cause of BUE. Any means of
reduction of friction such as use of lubricant & adhesion preventing agent is often effective to
reduce BUE, especially when it is necessary to operate at low cutting speeds. Tool material with
inherent low coefficient of friction or a high polish on tool face can also reduce friction & hence
BUE. The conditions favourable for BUE chip are.
1) Ductile material
2) Low cutting speed.
3) Small rake angle of tool.
4) Dull cutting edge.
5) Coarse feed.
6) Insufficient cutting fluid.
7) High friction at chip tool interface.
4) Inhomogeneous Chip: These chips are produced owing to non uniform strain set up in
material during chip formation and they are characterized by notches on the free side of chip,
while the side adjoining the tool face is smooth. The shear deformation which occurs during
chip formation causes temperatures on shear plane to rise which in turn may decrease the
strength of material & cause further strain if the material is poor conductor. This process when
repeated several times results in a large strain at the point of initial strain. Then a new shear
plane will develop at some distance from first and deformation shifts to this point. The resultant
chip is bonded with regions of large and small strain. This is characteristic of metals suffering
marked decrease in yield strength with temperature and poor thermal conductivity. These chips
are produced while machining some steels and titanium alloys at medium cutting speeds.
Table 1.1. : Factors responsible for the formation of different types of chips.
Types of chips
Factors Discontinuous Continuous With BUE Inhomogeneous
1. Material Brittle Ductile Ductile Which Shows
decreased in Yield
Strength with temp. &
Thermal conductivity
medium.
2. Cutting speed Low High Low -
3. Tool geometry Small rake Large rake Small -
4. Friction - Lower Higher -
5. Chip thickness Large Small Small -
6. Cutting fluid - Efficient Poor -
7. Feed - - Coarse -
8. Cutting edge - Sharp Blunt -
a1 = AB
sin φ
a2 = AB sin cos (φ - γ )
a 2 1 cos (φ − γ )
= =
a1 r sin φ
cos φ cos γ + sin φ sin γ
=
sin φ
1
= cot φ cos γ + sin γ
r
1
− sin γ
cot φ =
r = 1 − r sin γ
cos γ r cos γ
r cos γ
tan φ =
1 − r sin γ
sin φ cos γ
Vs= V, Vs = V,
cos (φ − γ ) cos (φ − γ )
Fig 1.15 Velocities associated with chip formation
Applying sine rule we have,
V Vc Vs
= =
sin (90 − φ + γ ) sin (φ ) sin (90 − γ )
V Vc Vs
= =
cos (φ − γ ) sin (φ ) cos (γ )
V sin (φ ) V cos (γ )
∴Vc = ...and ...Vc =
cos (φ − γ ) cos (φ − γ )
1.12Shear Strain:
During the process of chip formation, each undeformed layer of material passes through the
shear plane and undergoes considerable plastic deformation. Shear strain "εε" can be defined as
the ratio of displacement of the layer ∆S along the shear plane to the thickness of layer '∆∆x'.
Thus shear strain can be related to the shear angle φ and rake angle "γ" by the following
equation:
∆s ∆x cot φ + ∆x tan(φ − γ ) cos γ
ε= = = Cot φ + tan (φ - γ) or ε=
∆x ∆x sin φ cos(φ − γ )
This relation can be obtained from the pack of inclined cards model suggested by Prof.
Pushpanen. In this model, the formation of chip and its motion along the tool face can be
visualized from an idealized model in which a stack of inclined (playing) cards is pushed against
the tool (fig.1.16). As the tool advances, segments which had been part of the work piece,
become part of the chip. From this figure it can be seen that card closest to the tool point slips to
a finite distance relative to the uncut material as tool point slips to a finite distance relative to the
uncut material as tool advances. As the tool point reaches the next card, the previously slipped
card moves up along the tool face as a part of the chip.
BA = BE + AE
cos(φ − (φ − γ )) cos(γ )
= =
sin(φ ). cos(φ − γ ) sin(φ ). cos(φ − γ )
vs cos γ
But from velocity relations we have, =
v cos φ − γ
vs
Hence ε=
v sin φ
1.13Undeformed chip thickness:
The undeformed chip thickness "a1" can be estimated by referring fig. 1.17. Where two
consecutive cuts have been shown and various parameters such as feed f, depth of cut d, width of
cut b, thickness of undeformed chip t & chip thickness tc have been marked. It can be easily seen
that the following relations exist.
t
a1= s.sin φp b=
sinφ p
It is clear that the uncut chip thickness depends upon the primary cutting edge angle as shown in
fig.1.18. In fig. 1.18 (c) a where φp = 900, the uncut chip thickness, a1= feed "s" (mm/rev ) &
width of cut b = depth of cut "t".
a2
a1 a1
s
s
a1=s
t b=t
φp s
φp=900
Another, alternative way of having an orthogonal system of the second kind is to have Fx=0
during radial turning or facing operation, when
R= Pz2 + Py2
Fig. 1.21b shows the disposition of cutting forces in plane orthogonal radial turning or facing
with γb = 0 and φp = 0.
Fig 1.21b Reduced orthogonal system of second kind in plane Π0, where
γb =0 & φp =00
However out of all the above three cases shown in fig 1.20 1.21a and 1.21b the cutting in the first
two cases is "non free" or 'restricted" type where the auxiliary cutting edge is also active in
causing deviation of chip flow direction from the orthogonal plane.
The contribution of auxiliary cutting edge is to deviate Fxy from the orthogonal plane.
This deviation is small & neglected if the depth of cut is very large compared to feed, such
process is called "Restricted Orthogonal cutting.
However during cutting of a thin pipe with a cutting edge whose length is
considered to be very large compared to the width of cut, a "pure" orthogonal cutting of first or
second kind could be obtained. The principal schemes of metal cutting shall be based on pure
orthogonal cutting from which schemes for oblique or other continuous and intermittent cutting
processes like drilling, milling, etc., can be derived by similarly principles.
In the lathe tool dynamometer the two components of the resultant force can be measured
by selecting suitable orthogonal cutting set up involving the facing of a pipe by a tool with zero
back rake angle. The resultant cutting force is carried by the shear plane as well as by chip tool
interface. On tool face "R" can be resolved into friction force "F" & normal force "N" and on
the shear plane "R" can be resolved into shear force, "Fs" inclined at an angle φ with direction
of tool travel or along the shear plane and backing up force "Fn" setup by material normal to
shear plane.
1.15 Merchant's Analysis (Theory) :
Earnest & Merchant (1941) analysed the mechanics of metal cutting in order to develop
mathematical relationship connecting the variable in metal cutting the model is based on the
minimization of rate of energy dissipation. To simplify the mathematical relationship he made
following assumptions:
1)-The chip behaves as a free body in stable equilibrium under the action of two equal, opposite
and collinear resultant forces viz. R & R’.
2)-The tool edge is sharp.
3)-The work material suffers deformation across a thin shear plane.
4)-This is no side spread (or the deformation is two-dimensional).
5)-There is uniform distribution of normal & shear forces on the shear plane &
6)-The work material is rigid, perfectly plastic (or behaves like ideal plastic)
7)-As, (shear plane area). Ts (shear stress) & "β" (Friction angle), are constant & are
independent of shear angle 'φ
From the concept of chip formation and measuring force Ft and Ff with a cutting tool
dynamometer, Merchant was able to build up a picture of forces acting in the region of cutting
which give rise to plastic deformation and sliding of the chip down the tool rake face.
The forces exerted by the work piece on the chip are
Fn - Compressive force on the shear plane.
Fs - Shear force on the shear plane.
The forces exerted by the tool on the chip are
N - Normal force at the rake face of tool.
F - Frictional force along the rake face of tool.
The forces acting on the tool and measured by dynamometer are
Fc - tangential or cutting force
Ft – Thrust or feed force
Angle γ is tool rake angle,φ is shear plane angle and β is the angle of friction
Merchant suggested a compact and easy way of representing the various components of the
resultant force inside a circle having the diameter equal to R. For convenience the resultant force
is moved to the tool point.Fr constructing the Merchant circle the cutting force and the thrust
force are drawn to some scale at right angles to each other the hypotenuse of the triangle formed
will be the resultant force R. The R’ will have same magnitude but direction opposite to R. The
value of shear angle can be estimated from the formula for φ. Thus knowing the direction of the
shear plane the values of the two components Fs and Fn can be graphically found out. Similarly
as the value of rake angle is known the magnitudes of the other two components F, N can also be
found out graphically. These components can also be estimated by mathematical formulae which
can be derived as under. Certain four constructions are made in the fig 1.23 to find the se
mathematical relationships as under.
i) AE is drawn perpendicular to OC.( Extended.)
ii) AF is drawn perpendicular to BC.
iii) BG is drawn perpendicular to OD.
iv) BH is drawn perpendicular to AG.
The various unknown components of the resultant force(Fs, Fn, F, & N) can mathematically be
expressed as a function of known components (Fc, & Ft) and known angles( φ and γ) as under.
Fs = OE – EC = OE – AF = Fc Cos φ - Ft Sin φ
Fn = BF + FC = BF + AE = Fc Sinφ + Ft Cosφ
F = OG + GD = OG + BH = Fc Sin γ + Ft Cos γ
N = AG – AH = Fc Cos γ - Ft Sin γ
µ =Coefficient of friction =Tanβ =F / N or β= Tan−µ
b.a1 b.a1
Sinφ = or.Shearplane..area = As =
As Sinφ
Average shear stress =τs = Fs / As = Sin φ.Fs / b.a1
Fc Sec ( β - γ )
τs = cos (φ + β − γ ) Sin(φ )
a1 .b
As β is assumed to be independent of φ .Thus the terms in the bracket are independent of φ.
For maximum shear stress we have to partially differentiate the above equation and equate it to
zero i. e.
dτs
=0
dφ
Fc Sec ( β - γ )
Cos (φ + β − γ )Cos(φ ) − Sin (φ + β − γ ) Sin(φ ) = 0
a1 .b
π
Tan (φ + β − γ ) = Tan ( − φ)
2
π
φ + β −γ = −φ
2
π γ β
φ= + −
4 2 2
For all practical purpose the φ =γ for γ>150 and the φ =150 for γ<150
Merchant observed no confirmation between the practical and theoretical values of shear angle.
Hence he reconsidered his last assumption and assumed that the shear stress along the shear
plane varies linearly with normal stress.
τ s = τ so + k σ n
Where τ so = τ s at σ n =0
He then derived the following equation
Cot(2φ + β − γ ) = K1
Or Cot(2φ + β − γ ) = K1
The energy consumed during cutting process is primarily utilized at the shear plane,
where plastic deformation takes place and at chip tool interface where friction resists the flow of
chip. The total energy per unit time (E) is approximately equal to the sum of shear energy (Es),
Friction energy (Ef) and negligible amount of energy required to curl the otherwise straight chip,
kinetic energy required to accelerate the chip, surface energy required to produce new surface
etc.
Thus, E = Es + Ef
The energy required per unit time per unit volume of metal removed per unit time is called
specific energy (e)
Thus total specific energy
e = E/ba1.t.v.
e = Fc V/b. a1.v., (Kg/mm/min)/(mm3/min.)
e = Fc/b. a1. kg/mm2
Similarly specific shear energy (es) & specific friction energy (ef) can be defined by the
following relations.
A tool dynamometer is a exact method of measuring cutting forces acting on the tool.
In most metal cutting dynamometers the total force is determined by measuring, during metal
cutting, the deflections or strains in the elements supporting the cutting tool. The dynamometer
design should be such that it gives strain or displacements large enough to be measured
accurately.
Types of Dynamometer:
i) Mechanical Dial Gauge type dynamometer
ii) Strain Gage type dynamometer
- A strain gauge dynamometer is more accurate than a mechanical dial gauge type
dynamometer.
- In most metal-cutting-force dynamometers the tool force is determined by measuring
the deflections or strains in the elements supporting cutting tool.
- It is essential that the instrument should have high rigidity and high natural
frequencies so that the dimensional accuracy of the cutting operation is maintained
and the tendency for chatter or vibrations, to occur during cutting is minimised.
- The dynamometer must however, give strains or displacements large enough to be
measured accurately. The design of the dynamometer depends, to a large extent on
the strain or deflection measuring device & instrumentation used.
- Formulae are available to convert these readings into changes in length, strain and
hence stresses to which surfaces or strain gauges were subjected.
- Following are the two sets of strain gauges, connected in two separate Wheatstone
bridges as;
i) To measure the vertical component of the applied force, gauges 1 to 4 are
mounted on the horizontal centre line of the half ring, when a vertical load is
applied, gauges 1 and 3 will record compressive strain and gauges 2 and 4 will
record tensile strain.
ii) To measure the horizontal component of the applied force, gauges 5 to 8 are
mounted on the sloping faces of the dynamometer, when a horizontal load is
applied, gauges 5 and 7 will record compressive strain and gauges 6 and 8 will
record tensile strain.
- Thus by recording the readings of strain gauges, the stresses and hence the forces Ft
and Fr can be calculated.
Meaning of Machinability:
The term machinability refers to the ease with which a metal can be machined to an acceptable
surface finish. Murphy defined machinability as “the ability of a material to be machined under
given set of cutting conditions”.
Materials with good machinability require little power to cut. Can be cut quickly, easily obtain a
good surface finish, and do not wear the tooling much. Such materials are said to be free
machinable.
Machinability can be difficult to predict exactly because machining process has so many
variables. Strong, tough materials are usually more difficult to machine, because greater force is
required to cut them.
ADVERTISEMENTS:
ii. Machining parameters (cutting speed, feed, depth of cut, lubrication, etc.)
It is stated that the material A is more machinable than material B, this can three different
meanings, as;
Therefore it is important to note that machinability is always defined with a particular set of
conditions.
For example:
Condition set 1:
(Better surface finish) Material A (High carbon steel) has more machinability than material B
(Mild Steel).
Now result may be reversed. Material B (Mild Steel) has more machinability than material A
(High carbon steel).
There are many factors affecting machinability, but no widely accepted way to quantify it.
Instead, machinability is generally measured on a case-by-case basic. The various tests
conducted to quantify machinability are tailored made to justify need of a specific manufacturing
facility.
Tool life is generally considered as an important measure of machinability. Higher the tool life
better is the machinability of a work material. Some standard tables and charts are available that
provide a reference for comparing the machinability of different materials. These tables usually
measures the machinability in terms of the cutting velocity for a given tool life. Machinability
ratings are based on a tool life of T = 60 minute.
Surface finish of machined work material is also an important measure of machinability specially
in case of finishing operations. More is the surface finish obtained; more will be the
machinability of the work material.
The machinability rating/index of different materials is taken relative to the standard index. The
machinability index of free cutting steel is considered as standard index and fixed at 100%.
Machinability index is based on a tool life of T = 1 minute.
Machinability index of any other materials can be found by using following relation:
Machinability index = [(Cutting speed for standard free-cutting steel for 1min tool life) /
(Cutting speed of metal for 1min tool life)] x 100
Some important and accountable factors which affect the machinability are following:
It includes:
i. Hardness.
ii. Microstructure.
v. Rigidity of holding.
It includes:
i. Tool geometry.
It includes:
i. Cutting speed.
ii. Feed.
Tool Life:
Definition –
Tool life generally indicates the amount of satisfactory performance or service rendered by a
fresh tool or a cutting point till it is declared failed.
(a) In R & D: Actual machining time (period) by which a fresh cutting tool (or point)
satisfactorily works after which it needs replacement or reconditioning. The modern tools hardly
fail prematurely or abruptly by mechanical breakage or rapid plastic deformation. Those fail
mostly by wearing process which systematically grows slowly with machining time. In that case,
tool life means the span of actual machining time by which a fresh tool can work before attaining
the specified limit of tool wear. Mostly tool life is decided by the machining time till flank wear,
VB reaches 0.3 mm or crater wear, KT reaches 0.15 mm.
(b) In industries or shop floor: The length of time of satisfactory service or amount of acceptable
output provided by a fresh tool prior to it is required to replace or recondition.
For R & D purposes, tool life is always assessed or expressed by span of machining time in
minutes, whereas, in industries besides machining time in minutes some other means are also
used to assess tool life, depending upon the situation, such as
• No. of pieces of work machined
• Total volume of material removed
• Total length of cut.
Wear and hence tool life of any tool for any work material is governed mainly by the level of the
machining parameters i.e., cutting velocity, (VC), feed, (so) and depth of cut (t). Cutting velocity
affects maximum and depth of cut minimum.
The usual pattern of growth of cutting tool wear (mainly VB), principle of assessing tool life and
its dependence on cutting velocity are schematically shown in Fig.
The tool life obviously decreases with the increase in cutting velocity keeping other conditions
unaltered as indicated in Fig.
If the tool lives, T1, T2, T3, T4 etc are plotted against the corresponding cutting velocities, V1,
V2, V3, V4 etc as shown in Fig. a smooth curve like a rectangular hyperbola is found to appear.
When F. W. Taylor plotted the same figure taking both V and T in log-scale, a more distinct
linear relationship appeared as schematically shown in Fig.With the slope, n and intercept, c,
Taylor derived the simple equation as VTn= C where, n is called, Taylor’s tool life exponent. The
values of both ‘n’ and ‘c’ depend mainly upon the tool-work materials and the cutting
environment (cutting fluid application). The value of C depends also on the limiting value of VB
undertaken ( i.e., 0.3 mm, 0.4 mm, 0.6 mm etc.)
Example of use of Taylor’s tool life equation Problem:
If in turning of a steel rod by a given cutting tool (material and geometry) at a given machining
condition (so and t) under a given environment (cutting fluid application), the tool life decreases
from 80 min to 20 min. due to increase in cutting velocity, VC from 60 m/min to 120 m/min.,
then at what cutting velocity the life of that tool under the same condition and environment will
be 40 min.?
In Taylor’s tool life equation, only the effect of variation of cutting velocity, VC on tool life has
been considered. But practically, the variation in feed (so) and depth of cut (t) also play role on
tool life to some extent.
Taking into account the effects of all those parameters, the Taylor’s tool life equation has been
modified as,
The values of the constants, CT, x, y and z are available in Machining Data Handbooks or can be
evaluated by machining tests.