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TECHNICAL PAPERS

A Mechanistic Force Model for Contour Turning

[+] Author and Article Information
Rohit G. Reddy, Shiv G. Kapoor, Richard E. DeVor

Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801

J. Manuf. Sci. Eng 122(3), 398-405 (Oct 01, 1999) (8 pages) doi:10.1115/1.1285900 History: Received December 01, 1997; Revised October 01, 1999
Copyright © 2000 by ASME
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References

Merchant,  M. E., 1944, “Basic Mechanics of the Metal-Cutting Process,” J. Appl. Mech. Trans. ASME, 66, pp. A–168.
Shaw,  M. C., Cook,  N. H., and Smith,  P. A., 1952, “The Mechanics of Three-Dimensional Cutting Operation,” Trans. ASME, 74, pp. 1055–1064.
Klamecki, B. E., 1973, Incipient Chip Formation in Metal Cutting—A Three Dimensional Finite Element Analysis, Ph.D. thesis, University of Illinois at Urbana-Champaign.
Lajczok, M. R., 1980, A Study of Some Aspects of Metal Machining Using the Finite Element Method, Ph.D. thesis, North Carolina State University.
Sabberwal, A. J. P., 1960, “Chip Section and Cutting Force During the Milling Operation,” in Ann. CIRP, pp. 197–203.
Kline,  W. A., DeVor,  R. E., and Lindberg,  J. R., 1982, “The Prediction of Cutting Forces in End Milling With Application to Cornering Cuts,” Int. J. Mach. Tool Des. Res., 22, No. 1, pp. 7–22.
Subramani, G., Suvada, R., Kapoor, S. G., DeVor, R. E., and Meingast, W., 1987, “A Model for the Prediction of Force System for Cylinder Boring Process,” in Proceedings of NAMRC 15, pp. 439–446.
Kuhl, M. J., 1987, “The Prediction of Cutting Forces and Surface Accuracy for the Turning Process, Master’s thesis,” University of Illinois at Urbana-Champaign.
Endres,  W. J., Sutherland,  J. W., DeVor,  R. E., and Kapoor,  S. G., 1990, “A Dynamic Model of the Cutting Force System in the Turning Process,” Mont. Control Manuf. Proc. ASME PED, 44, pp. 193–212.
Endres,  W. J., DeVor,  R. E., and Kapoor,  S. G., 1995, “A Dual-Mechanism Approach to the Prediction of Machining Forces, Part 1: Model Development,” ASME J. Eng. Ind., 117, No. 4, pp. 526–533.
Endres,  W. J., DeVor,  R. E., and Kapoor,  S. G., 1995, “A Dual-Mechanism Approach to the Prediction of Machining Forces, Part 2: Calibration and Validation,” ASME J. Eng. Ind., 117, No. 4, pp. 534–541.
Endres,  W. J., and Waldorf,  D. J., 1994, “The Importance of Considering Size Effect Along the Cutting Edge in Predicting the Effective Lead Angle for Turning,” in Trans. NAMRI SME, 22, pp. 65–72.
Beiswenger,  C. R., 1981, “Turning With a Round-Nosed Form Tool,” in Proc. NAMRC, 9, pp. 397–402.

Figures

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Cutting tool in current and previous positions in contour turning
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Chip width in Quadrant III
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Log quadratic relation between cutting velocity and specific cutting energy
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Workpiece with convex and concave contours for model validation
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Comparison of experimental and simulated X force
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Comparison of experimental and simulated Y force
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Comparison of experimental and simulated Z force
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Comparison of experimental and simulated resultant force
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Variation of (a) Chip load (b) Chip thickness, along the tool path
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Effect of workpiece curvature on the chip load
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Experimental workpiece and deformed chip at 0 deg and 90 deg
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Comparison of simulated resultant force for original and reversed tool path
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Two way diagrams for the interaction effects
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Comparison of experimental and simulated forces for different tool geometries
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Comparison of simulated resultant force with improved tool design for constant spindle speed and constant surface speed

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