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TECHNICAL PAPERS

A New Model and Analysis of Orthogonal Machining With an Edge-Radiused Tool

[+] Author and Article Information
Jairam Manjunathaiah, William J. Endres

Department of Mechanical Engineering and Applied Mechanics, University of Michigan, Ann Arbor, MI 48109-2125

J. Manuf. Sci. Eng 122(3), 384-390 (Sep 01, 1999) (7 pages) doi:10.1115/1.1285886 History: Received December 01, 1997; Revised September 01, 1999
Copyright © 2000 by ASME
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References

Schimmel, R. S., Manjunathaiah, J., and Endres, W. J., 2000, “An Experimental Investigation of the variability of Edge Hones and Their Effects on Machining Forces,” to appear, ASME J. Manu. Sci. Eng.
Bitans,  K., and Brown,  R. H., 1965, “An Investigation of the Deformation in Orthogonal Cutting,” Int. J. Mach. Tool Des. Res., 5, pp. 155–165.
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Manjunathaiah, J., and Endres, W. J., 1996, “Effects of a Honed Cutting Edge in Machining,” in Proceedings of the Second S. M. Wu Manufacturing Symposium, Ann Arbor, pp. 25–32, SME.
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Hsu,  T. C., 1966, “A Study of the Shear and Normal Stresses on a Cutting Tool,” J. Eng. Ind., 88, pp. 51–54.
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Waldorf, D. J., 1996, Shearing, Ploughing and Wear in Orthogonal Machining, Ph.D. thesis, University of Illinois.
Wu,  D. W., 1988, “Application of a Comprehensive Dynamic Cutting Force Model to Orthogonal Wave Generating Processes,” Int. J. Mech. Sci., 30, No. 8, pp. 581–600.
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Figures

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Connolly and Rubenstein’s cutting model
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Geometric model of the cutting process with an edge radius tool
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Velocity hodograph for the new geometric model for orthogonal cutting
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Force balance on the lower boundary of the shear zone
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Cutting force component versus uncut chip thickness for 70-30 brass [γo=−5 deg,V=7.8 mm/s]
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Thrust force component versus uncut chip thickness for 70-30 brass [γo=−5 deg,V=7.8 mm/s]
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Calculated normal stress factor k versus uncut chip thickness [θ=30 deg, ψ=20 deg]
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Calculated shear stress versus uncut chip thickness [θ=30 deg, ψ=20 deg]
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Predicted shear strain rate versus uncut chip thickness [θ=30 deg, ψ=20 deg]
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Log(S) versus Log(γ̇) [θ=30 deg, ψ=20 deg]
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Shear angle versus average rake angle for θ=50 deg. Machining data from Thomsen et al. 14.
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Changing strains with tools of different rake angle. Machining data from Thomsen et al. 14.
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A log-log plot of shear stress versus shear strain rate for θ=50 deg and ψ=20 deg. Machining data from Thomsen et al. 14.

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