An Experimental and Computational Study of Temperature and Strain Fields in Metal Cutting

2001 ◽  
Author(s):  
Alan T. Zehnder ◽  
Yogesh K. Potdar ◽  
Xiaomin Deng ◽  
Chandrakant Shet
Keyword(s):  
Spatial Resolution ◽  
Metal Cutting ◽  
Computational Study ◽  
Orthogonal Cutting ◽  
Critical Role ◽  
Rake Angle ◽  
General Purpose ◽  
Temperature Fields ◽  
Ir Detectors ◽  
Strain Fields

Abstract Metal cutting is a thermo-mechanically coupled process in which plasticity induced heating and friction play a critical role. In this paper, we outline a methodology that combines high resolution experiments with numerical simulations. The simulations were performed with a general purpose finite element code. With this code we evaluate the effects of chip-tool interface friction and rake angle on temperature and cutting force and show that results for residual stresses in the workpiece are consistent with experimental data. We hypothesize that by closely coupling simulations to fine scale spatial and temporal experimental measurements of temperature and strain fields, questions related to choice of parameters in FE simulations can be resolved. We have designed and conducted orthogonal cutting experiments to measure temperatures, using IR detectors, with a spatial resolution of 27 × 27 μm and time scale of 200 ns. Experimentally obtained temperature fields are compared with FE results. We also obtain deformation fields with a spatial resolution of 50 × 50 μm.

The Effect of Prior Cutting Conditions on the Shear Mechanics of Orthogonal Machining

1998 ◽  
Vol 120 (1) ◽  
pp. 13-20 ◽  
Author(s):  
R. Stevenson ◽  
D. A. Stephenson
Keyword(s):  
Material Properties ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Cnc Machining ◽  
Machining Process ◽  
Depth Of Cut ◽  
Prior History ◽  
Machining Conditions ◽  
The Difference

It has been proposed several times in the metal-cutting literature that the machining process is non-unique and that the instantaneous machining conditions depend on the prior machining conditions (e.g. depth of cut, rake angle etc.). To evaluate the validity of this concept, a series of experiments was conducted using a highly accurate CNC machining center. For these experiments, the machining conditions were changed during the course of an orthogonal cutting experiment in a repeatable manner and the measured forces compared as a function of prior history. Tests were conducted on several tempers of 1100 aluminum and commercial purity zinc to evaluate the effect of material properties on the machining response. It was found that the change in measured cutting forces which could be ascribed to prior machining history was less than 3 percent and that material properties, particularly work hardening response, had no discernible effect on the magnitude of the difference.

scholarly journals Analysis of critical negative rake angle and friction characteristics in orthogonal cutting of AL1060 and T2

2019 ◽  
Vol 103 (1) ◽  
pp. 003685041987806 ◽  
Author(s):  
Yanchun Ding ◽  
Guangfeng Shi ◽  
Hua Zhang ◽  
Guoquan Shi ◽  
Dongdong Han
Keyword(s):  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Flow Characteristics ◽  
Rake Angle ◽  
Machined Surface ◽  
Friction Characteristics ◽  
Model Based ◽  
Stagnant Region ◽  
Cutting Experiments

The stagnant region often appears in front of the tool cutting edge, which is caused by mechanical inlay and excessive pressing in plastic metal cutting with large negative rake angle tools at a low speed. It results in the change of the effective negative rake angle which can affect the flow characteristics of material, the quality of machined surface and the abrasion loss of cutting tools. However, the critical negative rake angle model based on the existence of the stagnant region has not been reported yet. Therefore, in order to investigate the critical negative rake angle value considering the stagnant region, a critical negative rake angle model based on the principle of minimum required energy is established, and the correctness of the theoretical model is verified by orthogonal cutting experiments. At the same time, the influence of the critical value of the large negative rake angle tool on the machined surface quality is studied through different cutting experiments. These experimental results show that the deviations of both experimental and theoretical critical negative rake angle are less than 5% during the orthogonally cutting of the aluminium (AL1060) and copper (T2) materials by the negative rake angle tool. Meanwhile, the critical negative rake angle is related to the adhesive friction coefficient of tool–workpiece contact surface. The analysis of friction characteristics shows that the deviation values of both theoretical and experimental critical negative rake angle are proportional to the coefficient of adhesive friction and the thickness of the stagnant region. Critical negative rake angle has a significant effect on roughness and residual stress of the machined surface.

The Influence of Extreme Speeds and Rake Angles in Metal Cutting

1963 ◽  
Vol 85 (1) ◽  
pp. 49-64 ◽  
Author(s):  
W. N. Findley ◽  
R. M. Reed
Keyword(s):  
Coefficient Of Friction ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Shear Plane ◽  
Rake Angle ◽  
Lateral Extrusion ◽  
Tool Force ◽  
Steep Decrease ◽  
Peak Value ◽  
Antimony Alloy

A study is presented of the effect of wide variations in speed of cutting and rake angle on orthogonal cutting of several metals—mainly a lead-antimony alloy. It was observed that enormous decreases in tool forces occurred in the lead-antimony with increase in speed from 6 to 3800 fpm, and decrease in rake angle from +30° to −60°. Explanations for these variations are proposed. An unusual observation was that a transition as speed increased from continuous to discontinuous chips occurred at large negative rake angles. Possible causes of this behavior are discussed. Another unusual observation was that a steep rise in tool force occurred with increase in speed for rake angles of 0° and +30°. The rise to a peak value was followed by an equally steep decrease in tool forces. Other observations discussed include the appearance of side spikes on the chips, chip curl, lateral extrusion of chips, influence of normal stress occurring on the shear plane, and the apparent coefficient of friction.

Measuring fracture toughness from machining tests

2009 ◽  
Vol 223 (12) ◽  
pp. 2861-2869 ◽  
Author(s):  
Y Patel ◽  
B R K Blackman ◽  
J G Williams
Keyword(s):  
Fracture Toughness ◽  
Aluminium Alloy ◽  
Coefficient Of Friction ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Shear Plane ◽  
Rake Angle ◽  
Sufficient Information ◽  
The Coefficient Of Friction ◽  
Adhesion Toughness

An analysis of the forces involved in orthogonal cutting or machining is presented in which yielding on a shear plane is assumed. The fracture toughness Gc is included and it is observed that Gc may be determined by measuring the cutting and transverse forces together with the chip thickness for a range of cutting depths. This latter measurement enabled the shear plane angle ϕ to be determined experimentally. A simplified version of the analysis is also given in which ϕ is predicted by a cutting force minimization scheme. Neither scheme requires any details of the friction condition to be known since the transverse force is sufficient information for any type to be included in the analysis. A friction model including a coefficient of friction and an adhesion toughness is also utilized. Data for both polymer and metal cutting are taken from the literature and Gc is determined. In some datasets the tool rake angle α is also varied and the values of Gc and the yield stress σY are found to be independent of α. The force minimization method gives a good estimate of ϕ for most polymers. For metals (aluminium alloy, steel, and brass) the method worked well. For aluminium alloy Gc was independent of α and the predicted and measured ϕ values agreed. For steel and brass this was not so. Gc was mostly independent of α except at low values where high values of Gc were observed. A constant value of the coefficient of friction was observed for each α value but values for both the coefficient of friction and the adhesion toughness varied significantly with increasing rake angle.

Effects of Strain Rate and Temperature in Orthogonal Metal Cutting

1966 ◽  
Vol 8 (3) ◽  
pp. 264-275 ◽  
Author(s):  
G. Boothroyd ◽  
J. A. Bailey
Keyword(s):  
Theoretical Analysis ◽  
Strain Rate ◽  
Metal Cutting ◽  
Single Phase ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Process ◽  
Strain Rates ◽  
Continuous Chip

A new theoretical analysis of the orthogonal cutting process is described which is based on the known behaviour of a single phase metal at high strains, strain rates and temperatures. The theoretical analysis applies to the case where a continuous chip is produced under non-lubricated conditions with the absence of a built-up edge on the tool face and indicates the important parameters in the cutting process. The theory is examined experimentally and its validity established. Finally, from a knowledge of the effects of strain rate and temperature on the yield stress of a single phase metal, the theory is used to predict the effects of changes in cutting speed and tool rake angle on the tool forces and geometry of the cutting process. These predictions are compared qualitatively with the results of cutting tests.

A Photoelastic Study of Stress Distribution During Orthogonal Cutting—Part 1: Workpiece Stress Distribution

1971 ◽  
Vol 93 (2) ◽  
pp. 527-537 ◽  
Author(s):  
S. Ramalingam ◽  
L. L. Lehn
Keyword(s):  
Stress Distribution ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Infinite Plate ◽  
Cutting Parameters ◽  
Surface Damage ◽  
Rake Angle ◽  
Plate Edge ◽  
Line Load ◽  
State Of Stress

This paper examines the stress distribution in the workpiece as a function of the cutting parameters associated with orthogonal cutting. It is shown that the state of stress which prevails in the workpiece during orthogonal cutting with a tool having a rake angle α, is equivalent to that which will prevail in a semi-infinite plate when a line load is applied to its edge in tension at an angle complementary to the rake angle, measured from the plate edge outer normal in the counterclockwise direction. The effect of this stress field on the surface damage accompanying metal cutting is discussed.

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

1985 ◽  
Vol 107 (1) ◽  
pp. 77-80 ◽  
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.

scholarly journals Analytical model of temperature distribution in metal cutting based on Potential Theory

2015 ◽  
Vol 6 (2) ◽  
pp. 89-94 ◽  
Author(s):  
F. Klocke ◽  
M. Brockmann ◽  
S. Gierlings ◽  
D. Veselovac
Keyword(s):  
Potential Theory ◽  
Analytical Model ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Temperature Fields ◽  
Wear Behaviour ◽  
Work Piece ◽  
Machining Processes ◽  
Major Interest ◽  
Cutting Processes

Abstract. Temperature fields evolving during metal cutting processes have also been of major interest. Temperatures in the tool influence the wear behaviour and hence costs, temperatures in the work-piece are directly responsible for later product quality. Due to the high significance of temperatures, many modelling attempts for temperature fields have been conducted, however failed to deliver satisfying results. The present paper describes a novel analytical model using complex functions based on potential theory. Relevant heat sources in metal cutting as well as changing material constants are considered. The model was validated by an orthogonal cutting process and different real machining processes.

scholarly journals Smoothed Particle Hydrodynamics Simulation of Orthogonal Cutting with Enhanced Thermal Modeling

2021 ◽  
Vol 11 (3) ◽  
pp. 1020
Author(s):  
Mohamadreza Afrasiabi ◽  
Hagen Klippel ◽  
Matthias Roethlin ◽  
Konrad Wegener
Keyword(s):  
Smoothed Particle Hydrodynamics ◽  
Metal Cutting ◽  
Thermal Modeling ◽  
Orthogonal Cutting ◽  
Detection Algorithm ◽  
Mesh Free ◽  
Particle Hydrodynamics ◽  
Smoothed Particle ◽  
Boundary Treatments ◽  
Cutting Problems

Smoothed Particle Hydrodynamics (SPH) is a mesh-free numerical method that can simulate metal cutting problems efficiently. The thermal modeling of such processes with SPH, nevertheless, is not straightforward. The difficulty is rooted in the computationally demanding procedures regarding convergence properties and boundary treatments, both known as SPH Grand Challenges. This paper, therefore, intends to rectify these issues in SPH cutting models by proposing two improvements: (1) Implementing a higher-order Laplacian formulation to solve the heat equation more accurately. (2) Introducing a more realistic thermal boundary condition using a robust surface detection algorithm. We employ the proposed framework to simulate an orthogonal cutting process and validate the numerical results against the available experimental measurements.

A Computational Study of the Interaction of Melting Soil With Moisture Transport in the Native Soil

1998 ◽  
Author(s):  
Will Schreiber ◽  
John Kuo
Keyword(s):  
Heat Transfer ◽  
Heat Flow ◽  
Moisture Transport ◽  
Moving Boundary ◽  
Computational Study ◽  
Fluid Motion ◽  
Computer Code ◽  
General Purpose ◽  
Simple Method ◽  
Porous Soil

Abstract The current paper describes a computer model designed to analyze the moisture transport in the unmelted, porous soil neighboring a convecting melt. The time-dependent fluid and heat flow in the soil melt is simulated implicitly using the SIMPLE method generalized to predict viscous fluid motion and heat transfer on boundary-fitted, non-orthogonal coordinates which adapt with time. TOUGH2, a general-purpose computer code for multiphase fluid and heat flow developed by K. Pruess at Lawrence Berkekey Laboratory, has been modified for use on time-adaptive, boundary-fitted coordinates to predict heat transfer, moisture and air transport, and pressure distribution in the porous, unmelted soil. The soil melt model is coupled with the modified TOUGH2 model via an interface (moving boundary) whose shape is determined implicitly with the progression of time. The computer model’s utility is demonstrated in the present study with a special two-dimensional study. A soil initially at 20°C and partially-saturated with either a 0.2 or 0.5 relative liquid saturation is contained in a box two meters wide by ten meters high with impermeable bottom and sides. The upper surface of the soil is exposed to a 20°C atmosphere to which vapor and air can escape. Computation begins when the soil, which melts at 1700°C, is heated from one side (maintained at constant temperatures ranging from 1700°C to 4000°C). Heat from the hot wall causes the melt to circulate in such a way that the melt interface grows more rapidly at the top of the box than at the bottom. As the upper portion of the melt approaches the impermeable wall it creates a bottle neck for moisture release from the soil’s lower regions. The pressure history of the trapped moisture is examined as a means for predicting the potential for moisture penetration into the melt. The melt’s interface movement and moisture transport in the unmelted, porous soil are also examined.

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