Shearing, ploughing, and wear in orthogonal machining
Waldorf, Daniel James
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https://hdl.handle.net/2142/22648
Description
Title
Shearing, ploughing, and wear in orthogonal machining
Author(s)
Waldorf, Daniel James
Issue Date
1996
Doctoral Committee Chair(s)
Kapoor, Shiv G.
DeVor, Richard E.
Department of Study
Mechanical Science and Engineering
Discipline
Mechanical Science and Engineering
Degree Granting Institution
University of Illinois at Urbana-Champaign
Degree Name
Ph.D.
Degree Level
Dissertation
Keyword(s)
Engineering, Industrial
Engineering, Mechanical
Language
eng
Abstract
Under normal machining conditions, cutting forces are due primarily to the bulk shearing of the workpiece material in a narrow region called the shear zone. However, under certain conditions, such as finishing cuts or a worn tool, force components due to the rubbing and ploughing of the edge or wear land becomes significant. Predicting forces--and therefore other process outputs such as machined part quality--under these conditions requires an estimate of the effects of ploughing and wear. Furthermore, both ploughing and wear forces are thought to be related to machine-tool system stability through the process damping mechanism and to the machined workpiece surface properties. Little, however, is known about the effects of wear on forces, and even less on ploughing. No accepted model exists for predicting the effects of either.
Research will be presented which addresses both ploughing and wear. Ploughing is studied in terms of the appropriate model of material flow in the vicinity of the cutting edge. Experimental results show that a stable build-up of material adheres to the edge and diverts flow causing ploughing stresses on the bottom surface of the build-up. A slip-line field is then developed for ploughing force prediction based on the formation of the build-up. The model is further extended to account for a worn tool flank by considering the ploughing stresses at the cutting edge. Experiments on 6061-T6 aluminum alloy with varying flank wear land and edge radius are run to isolate the ploughing and wear force components and evaluate the ploughing and wear models. The results show great promise for understanding and quantifying the effects of edge radius and wear on cutting forces.
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