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TECHNICAL PAPERS

Extension of Oxley’s Analysis of Machining to Use Different Material Models

[+] Author and Article Information
Amir H. Adibi-Sedeh, Vis Madhavan, Behnam Bahr

College of Engineering, Wichita State University, Wichita, KS 67260-0035

J. Manuf. Sci. Eng 125(4), 656-666 (Nov 11, 2003) (11 pages) doi:10.1115/1.1617287 History: Received March 01, 2002; Revised June 01, 2003; Online November 11, 2003
Copyright © 2003 by ASME
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Figures

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Comparison of predicted (a) Cutting force, (b) Thrust force, and (c) Chip thickness with experimental data for Al 6061-T6 29. Cutting conditions: α=8°, b1=3.3 mm, different cutting speeds and undeformed chip thicknesses.
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Comparison of predicted (a) Cutting force, (b) Thrust force, and (c) Chip thickness with experimental data for Al 6082-T6 25. Cutting conditions: α=8°, different cutting speeds and undeformed chip thicknesses.
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Comparison of the temperature of the shear plane with experimental data 25 for Al 6082-T6 for different undeformed chip thicknesses. Cutting conditions: α=6°, V=6 m/s and different undeformed chip thicknesses. Note that the measured temperature seems to be close to the temperature at the end of the primary shear zone.
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Comparison of predicted (a) Specific cutting force, and (b) Shear plane angle using different material models with Oxley’s original model 12 and experimental data 12 for 0.45% carbon steel. Cutting conditions: α=−5°, V=7 m/s and different undeformed chip thicknesses. Oxley’s original model performs better compared to modified model with different material models. Among different material models used the Johnson-Cook material model shows the most sensitivity with respect to changes in undeformed chip thickness.
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Comparison predicted (a) Cutting force, and (b) Temperature of the tool-chip interface using different material models with Oxley’s original model 31 and experimental data 30 for 0.45% carbon steel. Cutting conditions: α=5°, t1=0.2 mm,b1=3 mm and different cutting speeds. Oxley’s original model underpredicts both cutting force and temperature along the tool-chip interface. The Johnson-Cook and Maekawa material models perform better in prediction of the cutting force and temperature respectively.
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Comparison of predicted (a) Cutting force, and (b) Thrust force with experimental data 33 for copper. Cutting conditions: α=8°, b1=1.17 mm, different cutting speeds and undeformed chip thicknesses.
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Variation of shear strength along the thickness of the primary shear zone predicted by the model for Al 2024-T3. Cutting conditions: α=8°, t1=160 μm,V=1.31 m/s and b1=4.7 mm. Note that the shear strength at the midplane of the shear zone, kAB, is different from the energy equivalent shear strength τs.
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Effect of the new modifications to Oxley’s model on (a) Cutting force, (b) Thrust force, and (c) Chip thickness. Cutting conditions: α=5°, t1=0.5 mm,b1=4 mm and 0.2% carbon steel. It can be seen that even though we have eliminated the degree of freedom provided by the parameter η, the predictions are slightly improved for cutting force and chip thickness.
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Comparison of predicted (a) Cutting force, (b) Thrust force, and (c) Chip thickness with experimental data for Al 2024-T3 29. Cutting conditions: α=0° and b1=4.7 mm, different cutting speeds and undeformed chip thicknesses.
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Comparison of predicted (a) Cutting force, (b) Thrust force with experimental data for Al 2024-T3 29. Cutting conditions: V=1.31 m/s and b1=4.1 mm, different rake angles and undeformed chip thicknesses.
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(a) Comparison of the size effect predicted by the model with the experimental data for Al 2024-T3 29, and (b) The decrease in specific cutting energy with increase in undeformed chip thickness can be attributed to the increase in shear angle, caused by the increase in temperature at the tool-chip interface and the consequent decrease in kchip. Cutting conditions: α=8°, V=2.62 m/s and b1=4.1 mm.
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Model of chip formation used in Oxley’s analysis for orthogonal machining 12
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Temperature variation along the thickness of the primary shear zone predicted by the modified model for Al 2024-T3. Cutting conditions: α=8°, t1=160 μm,V=1.31 m/s and b1=4.7 mm. β=0.38, εAB=0.63. Average temperature=110.7°C, temperature of the middle of the shear zone=117.7°C and η=0.54.

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