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TECHNICAL PAPERS

An Analytical Representation of Chip Area for Corner-Radiused Tools Under Both Depth-of-Cut and Feed Variations

[+] Author and Article Information
O. Burak Ozdoganlar, William J. Endres

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

J. Manuf. Sci. Eng 122(4), 660-665 (Dec 01, 1999) (6 pages) doi:10.1115/1.1286470 History: Received December 01, 1997; Revised December 01, 1999
Copyright © 2000 by ASME
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References

Merchant,  M. E., 1944, “Basic Mechanics of Metal Cutting Process,” ASME J. Appl. Mech., 66, pp. A168–A175.
Young,  H. T., Mathew,  P., and Oxley,  P. L. B., 1989, “Allowing for Nose Radius Effects in Prediction Chip Flow Direction and Cutting Forces in Bar Tuning,” Inst. Mech. Eng., Part C, 201 (C3), pp. 42–49.
Zhang,  G. M., and Kapoor,  S. G., 1987, “Dynamic Modeling and Analysis of the Boring Machining System,” ASME J. Eng. Ind., 109, pp. 219–226.
DeVor,  R. E., Kapoor,  S. G., Fu,  H. J., and Subbarao,  P. C., 1983, “Effect of Variable Chip Load on Machining Performance in Face Milling,” NAMRI/SME, 11, pp. 348–355.
Subramani, G., Kapoor, S. G., DeVor, R. E., and Hayashida, R., 1987, “An Enhanced Model for the Simulation of Face Milling Operations,” Proceedings, 2nd International Conference on Computer-Aided Production Engineering, pp. 42–49.
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,” NAMRI/SME,15, pp. 439–446.
Tansel,  I. N., 1993, “A Unified Transfer Function (UTF) Approach for the Modeling and Stability Analysis of Long Slender Bars in 3-D Turning Operations,” ASME J. Eng. Ind., 115, pp. 193–204.
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,” ASME Symposium on Monitoring and Control for Manufacturing Processes, Vol. PED 44 , pp. 193–212.
Radulescu, R. C., 1993, “A General Cutting Process Model for High-Speed Machining: Dynamics and Thermal Considerations,” Ph.D. thesis, University of Illinois at Urbana-Champaign, Urbana, IL.
Gu, F., 1994, “Prediction of Cutting Forces and Surface Errors in Face Milling with Generalized Cutter and Workpiece Geometry,” Ph.D. thesis, University of Illinois at Urbana-Champaign, Urbana.

Figures

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Traditional simple representation of the corner-radiused chip area
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Chip-area geometry with depth-direction variation Δd, where Δd=Δd0−Δd1
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Finite-positive validity constraints
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Exact area calculation using geometric shapes
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Comparison of the percent errors with those of the alternate expressions
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Non-dimensional errors for ψr=−45°
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Effect of the lead angle (labeled −45° to 30°) on absolute error

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