Mechanics of Orthogonal Machining: Predicting Chip Geometry and Cutting Forces from Work-Material Properties and Cutting Conditions

1969 ◽  
Vol 184 (1) ◽  
pp. 927-942 ◽  
Author(s):  
R. G. Fenton ◽  
P. L. B. Oxley
Keyword(s):  
Excellent Agreement ◽  
Material Properties ◽  
Cutting Forces ◽  
Contact Length ◽  
Experimental Results ◽  
Cutting Conditions ◽  
Orthogonal Machining ◽  
Work Material ◽  
Wide Range ◽  
Chip Geometry

A recently developed theory of orthogonal machining is used to calculate chip geometry (including tool-chip contact length) and cutting forces for SAE 1112 steel over a wide range of cutting conditions. A comparison with experimental results shows excellent agreement for most of the cutting conditions considered.

Mechanics of Oblique Machining: Predicting Chip Geometry and Cutting Forces from Work Material Properties and Cutting Conditions

1972 ◽  
Vol 186 (1) ◽  
pp. 813-820 ◽  
Author(s):  
G. C. I. Lin ◽  
P. L. B. Oxley
Keyword(s):  
Plastic Deformation ◽  
Flow Stress ◽  
Material Properties ◽  
Cutting Conditions ◽  
Approximate Theory ◽  
Plane Normal ◽  
Orthogonal Machining ◽  
Work Material ◽  
Chip Flow ◽  
Chip Geometry

An approximate theory of oblique machining is obtained by assuming that the plastic deformation in the plane normal to the cutting edge is equivalent to the flow in orthogonal machining. Equations are derived from which the chip geometry, including the direction of chip flow, and the three components of cutting force can be calculated for given cutting conditions and material properties. Results of machining tests are used to calculate the flow stress properties of the work material which are then used with the oblique machining theory to predict forces etc. Predicted and experimental results are shown.

A Quantitative Sensitivity Analysis of Cutting Performances in Orthogonal Machining with Restricted Contact and Flat-Faced Tools

2004 ◽  
Vol 126 (2) ◽  
pp. 408-411
Author(s):  
Ning Fang
Keyword(s):  
Sensitivity Analysis ◽  
Slip Line ◽  
Cutting Forces ◽  
Chip Thickness ◽  
Contact Length ◽  
Machining Parameters ◽  
Flow Angle ◽  
Orthogonal Machining ◽  
Different Types ◽  
Machining Operations

This paper presents a new quantitative sensitivity analysis of cutting performances in orthogonal machining with restricted contact and flat-faced tools, based on a recently developed slip-line model. Cutting performances are comprehensively measured by five machining parameters, i.e., the cutting forces, the chip back-flow angle, the chip up-curl radius, the chip thickness, and the tool-chip contact length. It is demonstrated that the percentage of contribution of tool-chip friction to the variation of cutting performances depends on different types of machining operations. No general conclusion about the effect of tool-chip friction should be made before specifying a particular type of machining operation and cutting conditions.

A machining theory for predicting chip geometry, cutting forces etc. from work material properties and cutting conditions

1980 ◽  
Vol 371 (1747) ◽  
pp. 569-587 ◽  
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Cutting Speed ◽  
Carbon Steels ◽  
Cutting Conditions ◽  
Strain Rates ◽  
Compression Tests ◽  
Rate Dependent ◽  
Work Material ◽  
Flow Stress Data

An approximate machining theory is described in which account is taken of the temperature and strain-rate dependent properties of the work material. A feature of the theory is that the strain rates in the zones of intense plastic deformation in which the chip is formed and along the tool/ chip interface are determined as part of the solution. The theory is applied to make predictions for two plain carbon steels and a range of cutting conditions by using flow stress data obtained from high speed compression tests and excellent agreement is shown, for example, between predicted and experimental cutting forces. The values of tool/chip interface plastic zone thickness predicted by assuming a minimum work criterion are shown to agree well with experimental values, both experiment and theory indicating a marked decrease in thickness with increase in cutting speed. It is also shown how the temperatures and strain rates in this zone can be used to determine the conditions that cause a built-up edge to be formed on the cutting tool and good agreement is again shown with experimental results.

Modeling and Experimental Analysis of Acoustic Emission from Metal Cutting

1989 ◽  
Vol 111 (3) ◽  
pp. 229-237 ◽  
Author(s):  
R. Teti ◽  
D. Dornfeld
Keyword(s):  
Acoustic Emission ◽  
Experimental Analysis ◽  
Metal Cutting ◽  
Experimental Results ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Simple Manner ◽  
Work Material ◽  
Theoretical Predictions

Testing parameters characterizing acoustic emission (AE) detected during metal cutting may be theoretically correlated, in a simple manner, to work material properites, cutting conditions, and tool geometry. Experimental results, obtained during turning by different researchers using different AE techniques, are presented and critically assessed with reference to their reciprocal agreement as well as their agreement with theoretical predictions. A review of current methods for AE analysis is also presented and the correlations between different AE parameters and energy and power of the detected signals are reported.

scholarly journals Numerical and experimental investigation of Johnson–Cook material models for aluminum (Al 6061-T6) alloy using orthogonal machining approach

2018 ◽  
Vol 10 (9) ◽  
pp. 168781401879779 ◽  
Author(s):  
Sohail Akram ◽  
Syed Husain Imran Jaffery ◽  
Mushtaq Khan ◽  
Muhammad Fahad ◽  
Aamir Mubashar ◽  
...  
Keyword(s):  
Coefficient Of Friction ◽  
Cutting Forces ◽  
High Speed ◽  
Material Model ◽  
Material Behavior ◽  
Experimental Results ◽  
Model Parameters ◽  
Al 6061 ◽  
Orthogonal Machining ◽  
Cutting Speeds

This research focuses on the study of the effects of processing conditions on the Johnson–Cook material model parameters for orthogonal machining of aluminum (Al 6061-T6) alloy. Two sets of parameters of Johnson–Cook material model describing material behavior of Al 6061-T6 were investigated by comparing cutting forces and chip morphology. A two-dimensional finite element model was developed and validated with the experimental results published literature. Cutting tests were conducted at low-, medium-, and high-speed cutting speeds. Chip formation and cutting forces were compared with the numerical model. A novel technique of cutting force measurement using power meter was also validated. It was found that the cutting forces decrease at higher cutting speeds as compared to the low and medium cutting speeds. The poor prediction of cutting forces by Johnson–Cook model at higher cutting speeds and feed rates showed the existence of a material behavior that does not exist at lower or medium cutting speeds. Two factors were considered responsible for the change in cutting forces at higher cutting speeds: change in coefficient of friction and thermal softening. The results obtained through numerical investigations after incorporated changes in coefficient of friction showed a good agreement with the experimental results.

Prediction of Chip Flow Direction and Cutting Forces in Oblique Machining with Nose Radius Tools

1995 ◽  
Vol 209 (4) ◽  
pp. 305-315 ◽  
Author(s):  
J A Arsecularatne ◽  
P Mathew ◽  
P L B Oxley
Keyword(s):  
Cutting Forces ◽  
Flow Direction ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Chip Flow ◽  
Wide Range ◽  
Predicted Values ◽  
Edge Based

A method is described for calculating the chip flow direction in terms of the tool cutting edge geometry and the cutting conditions, namely feed and depth of cut. By defining an equivalent cutting edge based on the chip flow direction it is then shown how cutting forces can be predicted given the work material's flow stress and thermal properties. A comparison between experimental results obtained from bar turning tests and predicted values for a wide range of tool geometries and cutting conditions shows good agreement.

Relation between the ratio of elastic work to the total work of indentation and the ratio of hardness to Young's modulus for a perfect conical tip

2009 ◽  
Vol 24 (3) ◽  
pp. 590-598 ◽  
Author(s):  
J. Chen ◽  
S.J. Bull
Keyword(s):  
Numerical Simulation ◽  
Elastic Modulus ◽  
Linear Relationship ◽  
Young’S Modulus ◽  
Excellent Agreement ◽  
Material Properties ◽  
Experimental Results ◽  
Total Work ◽  
Scaling Relationship ◽  
Reduced Modulus

A linear relationship between the ratio of elastic work to the total indentation work and hardness to reduced modulus, i.e., We/Wt = λ H/Er, has been derived analytically and numerically in a number of studies and has been widely accepted. However, the scaling relationship between We/Wt and H/Er has recently been questioned, and it was found that λ is actually not a constant but is related to material properties. In this study, a new relationship between We/Wt and H/Er has been derived, which shows excellent agreement with numerical simulation and experimental results. We also propose a method for obtaining the elastic modulus and hardness of a material without invoking the commonly used Oliver and Pharr method. Furthermore, it is demonstrated that this method is less sensitive to tip imperfections than the Oliver and Pharr approach is.

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