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TECHNICAL PAPERS

Application of an Internally Consistent Material Model to Determine the Effect of Tool Edge Geometry in Orthogonal Machining

[+] Author and Article Information
Roy J. Schimmel, William J. Endres

Dept. of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125

Robin Stevenson

Enterprise Systems Laboratory, General Motors R & D Center, Warren, MI 48090-9055e-mail: rstevenson@gmr.com

J. Manuf. Sci. Eng 124(3), 536-543 (Jul 11, 2002) (8 pages) doi:10.1115/1.1448334 History: Received February 01, 1999; Revised May 01, 2001; Online July 11, 2002
Copyright © 2002 by ASME
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References

Figures

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Typical cutting and thrust force signatures during feed dwell tests
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Typical cutting and thrust force signatures from CNC step test
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Shear angle vs. uncut chip thickness (5 deg rake, 256 rpm)
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Forces vs. uncut chip thickness (5 deg rake, 256 rpm): (a) cutting (b) thrust
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Shear stress vs. shear-strain rate (log-log) for all sharp tool data
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Shear stress vs. shear-strain rate (log-log) across edge radii (5 deg rake, 256 rpm)
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Dwell forces vs. uncut chip thickness (5 deg rake, 256 rpm): (a) cutting FCd, (b) thrust FTd
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Shear stress vs. shear-strain rate (log-log) for dwell-corrected nominal stress (256 rpm) at nominal rake angles of: (a) +5 deg (b) −16 deg
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Shear stress vs. shear-strain rate (log-log) for extrapolation-corrected nominal stress (5 deg rake, 256 rpm)
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Schematic of an equivalent rake angle and shear angle
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Video images from CNC step test (80 μm edge radius, 5 deg rake, 256 rpm)—numeric values are the uncut chip thickness in μm, arrows indicate direction of chip departure from tool
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Shear stress vs. shear-strain rate (log-log) for stress calculated using equivalent rake angle only (5 deg rake, 256 rpm)
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Shear stress vs. shear-strain rate (log-log) for stress calculated using equivalent rake angle and shear zone thickening (5 deg rake, 256 rpm)
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Micrographs of quick stop tests for an 80 μm edge radius and a 377 μm uncut chip thickness at rake angles of: (a) 5 deg, (b) 0 deg, and (c) −16 deg

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