A three-zone model and solution of shear angle in orthogonal machining

Zhang, Hongti; Liu, P.D.; Hu, Rui

doi:10.1016/0043-1648(91)90083-7

Cited by 37 publications

(23 citation statements)

References 10 publications

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“…This leads to an increase in chip velocity. However as the chamfer angle increases, chip thickness remains unchanged and this supports the previous work by other researchers [5]. From Figs.…”

Section: Chip Thickness and Shear Anglesupporting

confidence: 91%

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Machining with chamfered tools

Choudhury

See

Zukhairi

2005

Journal of Materials Processing Technology

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Section: Chip Thickness and Shear Anglesupporting

confidence: 91%

“…The mechanics of machining with chamfered tools have been analyzed by Zhang et al [5]. They considered the primary, dead metal, and deformation zone separately and concluded that existence of dead metal zone was not dependent on the cutting speed, tool main rake angle or the chamfer angle.…”

Section: Introductionmentioning

confidence: 99%

Machining with chamfered tools

Choudhury

See

Zukhairi

2005

Journal of Materials Processing Technology

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“…A finite radius on the cutting edge was believed to be responsible by contributing additional forces as some material was directed downward below the edge and pressed into the workpiece. Although the discovery of a secondary shear zone at the tool-chip interface changed the view of friction at that interface, ploughing and its importance in cutting became the subject of a number of investigations (Palmer and Yeo, 1963;Johnson, 1967;Moneim and Scrutton, 1974;Heginbotham and Gogia, 1961) and continue to be studied (Rubenstein, 1990;Zhang et al, 1991;Sawar and Thompson, 1981;Parthimos et al, 1993;Wu, 1988;Endres et al, 1995;Elanayar and Shin, 1994) as researchers attempt to gain a complete understanding of the mechanisms of the cutting process. For example, a size effect on cutting forces has long been observed, in which the ratio of forces to the area of cut increases as uncut chip thickness decreases.…”

Section: Introductionmentioning

confidence: 99%

“…This, however, has not generally been observed during orthogonal cutting. Still other models (Palmer and Yeo, 1963;Moneim and Scrutton, 1974;Zhang et al, 1991;Sarwar and Thompson, 1981) predict plastic flow beneath the edge and postulate a stable build-up of material adhered to the edge. Each of these theories/models has used plasticity methods and slip-line fields to model the flow, but the experimental difficulties of isolating the ploughing force components has resulted in very little verification of the models.…”

Section: Introductionmentioning

confidence: 99%

A Slip-Line Field for Ploughing During Orthogonal Cutting

Waldorf¹,

DeVor

Kapoor

1998

Journal of Manufacturing Science and Engineering

241

126

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Under normal machining conditions, the cutting forces are primarily due to the bulk shearing of the workpiece material in a narrow zone called the shear zone. However, under finishing conditions, when the uncut chip thickness is of the order of the cutting edge radius, a ploughing component of the forces becomes significant as compared to the shear forces. Predicting forces under these conditions requires an estimate of ploughing. A slip-line field is developed to model the ploughing components of the cutting force. The field is based on other slip-line fields developed for a rigid wedge sliding on a half-space and for negative rake angle orthogonal cutting. It incorporates the observed phenomena of a small stable build-up of material adhered to the edge and a raised prow of material formed ahead of the edge. The model shows how ploughing forces are related to cutter edge radius -a larger edge causing larger ploughing forces. A series of experiments were run on 6061-T6 aluminum using tools with different edge radii -including some exaggerated in size -and different levels of uncut chip thickness. Resulting force measurements match well to predictions using the proposed slip-line field. The results show great promise for understanding and quantifying the effects of edge radius and worn tool on cutting forces.

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“…Ploughing has also been examined for its own contribution to cutting forces [Bitans 1965;Johnson 1967;AbdelMoneim 1974;Sarwar 1981;Rubenstein 1990;Zhang 1991;Endres 1995;Wang 2002] and its relationship to worn tool flank forces [Usui 1984;Elanayar 1994].…”

Section: Introductionmentioning

confidence: 99%

A Simplified Model for Ploughing Forces in Turning

Waldorf

2006

Journal of Manufacturing Processes

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This paper aims to provide experimental data in support of a modified theoretical model for quantifying the effect of cutting tool edge geometry on machining forces. A previously published slip-line model is simplified and extended to the case of turning. Several sets of machining experiments were run with customfabricated cutting inserts of varying edge hone radius and chamfer geometry. Cutting forces were measured using a dynamometer during cutting.Results show that varying edge geometry can have a major effect on cutting forces.The developed model effectively captures the edge phenomenon and its effect on cutting forces and also offers a glimpse of how the edge geometry can affect dynamic process damping.

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A three-zone model and solution of shear angle in orthogonal machining

Cited by 37 publications

References 10 publications

Machining with chamfered tools

Machining with chamfered tools

A Slip-Line Field for Ploughing During Orthogonal Cutting

A Simplified Model for Ploughing Forces in Turning

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