Edge Forces in Metal Cutting: Fundamental Analysis and Experimental Verification

Abstract In metal cutting, some of the generated forces do not contribute to chip formation. These forces are referred to as plowing forces and are induced mainly as result of the finite sharpness of the tool (cutting edge radius) and the tool’s land (flank). Determining the magnitude of these forces is essential to developing a better understanding of the mechanics and physics of applications that involve cutting at minimal feed values (e.g., micro-machining and vibration-assisted-micro-machining. It is well recognized that plowing forces increase with tool wear. This research estimates these forces by employing analytical and numerical simulations. An extensive experimental analysis is utilized to verify the simulated values of the plowing forces. The experimental verification is designed to measure these forces as a function of several cutting parameters. The developed methodology relates the plowing forces to geometric factors and process parameters such as cutting-edge radius, tool feed, and cutting speed.

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A treatise on material characterization in the metal cutting process. Part 1: A novel approach and experimental verification

Journal of Materials Processing Technology ◽

10.1016/s0924-0136(99)00252-6 ◽

1999 ◽

Vol 96 (1-3) ◽

pp. 22-33 ◽

Cited By ~ 15

Author(s):

Viktor P. Astakhov

Keyword(s):

Experimental Verification ◽

Material Characterization ◽

Metal Cutting ◽

Cutting Process ◽

Novel Approach

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Experimental Verification of a Catastrophe Theory Model of Metal Cutting Chip Formation

Journal of Engineering for Industry ◽

10.1115/1.3185969 ◽

1985 ◽

Vol 107 (1) ◽

pp. 77-80 ◽

Cited By ~ 3

Author(s):

B. E. Klamecki

Keyword(s):

Experimental Verification ◽

Chip Formation ◽

Metal Cutting ◽

Cutting Tool ◽

Orthogonal Cutting ◽

Rake Angle ◽

Theory Model ◽

Shear Angle ◽

Cutting Geometry ◽

Shear Energy

The problem of predicting changes in the chip formation process in metal cutting was considered. An analytical model which predicts the shear angle as the cutting tool approaches the end of the workpiece was developed. The model was of the orthogonal cutting geometry with shear along a plane and the shear angle predicted from a minimum shear energy postulate. The model predicted two shear angles near the end of cutting and these were compared with measured shear angles for cutting different work materials with varying rake angle tools.

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