Effect of stress distribution on the shear angle Φ in controlled contact orthogonal cutting

1982 ◽  
Vol 22 (2) ◽  
pp. 87-96 ◽  
Author(s):  
R.N. Mittal ◽  
B.L. Juneja
Keyword(s):  
Stress Distribution ◽  
Orthogonal Cutting ◽  
Shear Angle

Thermal-Mechanical Effect on Temperature/Stress Distribution when Orthogonal Cutting Bearing Steel

2009 ◽  
Vol 407-408 ◽  
pp. 420-423
Author(s):  
He Ping Wang ◽  
Xue Ping Zhang
Keyword(s):  
Stress Distribution ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Bearing Steel ◽  
Mechanical Effect ◽  
Arbitrary Lagrangian Eulerian ◽  
Calculation Results ◽  
On Chip ◽  
Explicit Dynamic

An explicit dynamic coupled thermal-mechanical Arbitrary Lagrangian Eulerian (ALE) model was established to simulate orthogonal cutting AISI 52100 bearing steel, and its temperature and stress distribution. Based on ABAQUS, The ALE approach effectively simulates plastic flow around round edge of the cutting tool without employing chip separation criteria. The calculation results reveal that cutting speed and cutting depth have great impact on chip morphology, stress and temperature distribution in the finished surface and subsurface, the predicted temperature agrees well with experiment data obtained under the similar cutting conditions as well as the change in chip morphology from continuous to sawtooth as the cutting speed increases.

Formation and Simulation of Cutting-Direction Burr in Orthogonal Cutting

2007 ◽  
Vol 24-25 ◽  
pp. 249-254 ◽  
Author(s):  
Hai Jun Qu ◽  
Gui Cheng Wang ◽  
Hong Jie Pei ◽  
Qin Feng Li ◽  
Yun Ming Zhu
Keyword(s):  
Shear Zone ◽  
Formation Process ◽  
Orthogonal Cutting ◽  
Shear Angle ◽  
Burr Formation ◽  
Size And Shape ◽  
Study Results ◽  
Edge Quality ◽  
And Performance ◽  
Cutting Direction

The cutting-direction burr is one of the important factors that influence the edge quality and performance of precision parts. The cutting-direction burr formation process is simulated with DeformTH3D. The mechanism of cutting-direction burr formation is analyzed in terms of the results of the simulation. The negative shear zone and initiation negative shear angle are discussed too. Study results show that the deformation of CDE is an important factor affect the cutting direction burrs’ size and shape.

Cyclic shear angle for lamellar chip formation in ultra-precision machining

2020 ◽  
Vol 234 (13) ◽  
pp. 2673-2680 ◽  
Author(s):  
Shaojian Zhang ◽  
Pan Guo ◽  
Zhiwen Xiong ◽  
Suet To
Keyword(s):  
Chip Formation ◽  
Diamond Tool ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Shear Angle ◽  
Precision Machining ◽  
Cyclic Shear ◽  
Intrinsic Mechanism ◽  
Classical Models ◽  
Ultra Precision

Shear angle is classically considered constant. In the study, a series of straight orthogonal cutting tests of ultra-precision machining revealed that shear angle cyclically evolved with each lamellar chip formation, i.e. cyclic shear angle. It grew up from an initial shear angle of 0° to a final shear angle 90°- α ( α: tool rake angle) and underwent a series of transient shear angles like classical shear angles and a critical shear angle. The critical shear angle is the sum of the half of the tool rake angle and the characteristic shear angle determined by material anisotropy without the friction effect. Moreover, a new model was developed. Further, a series of face turning tests of ultra-precision machining verified that the cyclic shear angle was the intrinsic mechanism of cyclic cutting forces and lamellar chip formation to induce twin-peak high-frequency multimode diamond-tool-tip vibration. Significantly, the study draws up an understanding of shear angle for the discrepancy among the classical models.

Residual Stress Prediction by Means of 3D FEM Simulation

2011 ◽  
Vol 223 ◽  
pp. 431-438 ◽  
Author(s):  
Aldo Attanasio ◽  
Elisabetta Ceretti ◽  
Cristian Cappellini ◽  
Claudio Giardini
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Stress Measurement ◽  
Numerical Models ◽  
Orthogonal Cutting ◽  
Residual Stress Distribution ◽  
Tool Geometry ◽  
Distribution Analysis ◽  
3D Fem ◽  
Workpiece Material

In cutting field, residual stress distribution analysis on the workpiece is a very interesting topic. Indeed, the residual stress distribution affects fatigue life, corrosion resistance and other functional aspects of the workpiece. Recent studies showed that the development of residual stresses is influenced by the cutting parameters, tool geometry and workpiece material. For reducing the costs of experimental tests and residual stress measurement, analytical and numerical models have been developed. The aim of these models is the possibility of forecasting the residual stress distribution into the workpiece as a function of the selected process parameters. In this work the residual stress distributions obtained simulating cutting operations using a 3D FEM software and the corresponding simulation procedure are reported. In particular, orthogonal cutting operations of AISI 1045 and AISI 316L steels were performed. The FEM results were compared with the experimental residual stress distribution in order to validate the model effectiveness.

scholarly journals Experimental investigation of the shear angle variation during orthogonal cutting

2018 ◽  
Vol 5 (13) ◽  
pp. 26495-26500 ◽  
Author(s):  
Szabolcs Berezvai ◽  
Tamas G. Molnar ◽  
Daniel Bachrathy ◽  
Gabor Stepan
Keyword(s):  
Experimental Investigation ◽  
Orthogonal Cutting ◽  
Shear Angle ◽  
Angle Variation

Crystal anisotropy-dependent shear angle variation in orthogonal cutting of single crystalline copper

2020 ◽  
Vol 63 ◽  
pp. 41-48 ◽  
Author(s):  
Zhanfeng Wang ◽  
Junjie Zhang ◽  
Zongwei Xu ◽  
Jianguo Zhang ◽  
Guo Li ◽  
...  
Keyword(s):  
Orthogonal Cutting ◽  
Shear Angle ◽  
Angle Variation ◽  
Single Crystalline ◽  
Crystal Anisotropy

Investigation of shear angle in orthogonal cutting using FE simulation

2020 ◽  
Vol 2020.69 (0) ◽  
pp. 304
Author(s):  
Takumi KUIKITA ◽  
Makoto NIKAWA ◽  
Minoru YAMASHITA
Keyword(s):  
Fe Simulation ◽  
Orthogonal Cutting ◽  
Shear Angle

FEM Analysis of Residual Stress Distribution and Cutting Forces in Orthogonal Cutting with Different Initial Stresses

2014 ◽  
Vol 800-801 ◽  
pp. 380-384 ◽  
Author(s):  
Yuan Ma ◽  
Ding Wen Yu ◽  
Ping Fa Feng
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Compressive Stress ◽  
Cutting Forces ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Fem Simulation ◽  
Fem Analysis ◽  
Cutting Parameters ◽  
Initial Stresses

Machining induced residual stress is influenced by many factors. Extensive studies on the influence of cutting parameters, tool parameters, as well as basic properties of materials have been carried out during the past decades, while another important factor, initial stress distribution in workpiece, was often ignored. In this paper a relatively complete FEM simulation on the formation mechanism of machining induced residual stress in high speed machining is carried out, illustrating the three stress zones affected by mechanical and thermal loads, and their influence on ultimate residual stress. And the influence of initial compressive stress on stress formation and cutting forces is analyzed. Initial compressive stress weakens the tensile effect caused by the shear deformation, and the residual stress tend to be more compressive with larger initial compressive stress. Cutting force becomes larger with the increase of initial compressive stress. And the results in this FEM study can be used to explain some unaccounted experimental phenomena in former researches.

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