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TECHNICAL PAPERS

Analysis of the Cutting Force Components and Friction in High Speed Machining

[+] Author and Article Information
G. Sutter, A. Molinari

L.P.M.M., U.M.R. C.N.R.S. n°7554, I.S.G.M.P., Université de Metz Ile du Saulcy, 57045 Metz Cedex 1, France

J. Manuf. Sci. Eng 127(2), 245-250 (Apr 25, 2005) (6 pages) doi:10.1115/1.1863253 History: Received October 05, 2004; Online April 25, 2005
Copyright © 2005 by ASME
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References

Sutter,  G., Molinari,  A., Faure,  L., Klepaczko,  J. R., and Dudzinski,  D., 1998, “An Experimental Study of High Speed Orthogonal Cutting,” ASME J. Manuf. Sci. Eng., 120, pp. 169–172.
Merchant,  E., 1945, “Mechanics of the Metal Cutting Process. I. Orthogonal Cutting and a Type 2 Chip,” J. Appl. Phys., 16(5), pp. 267–324.
Kottenstette, J. P., and Recht, R. F., 1982, “Ultra-High-Speed Machining Experiments,” Proceedings, Ninth North American Manufacturing Research Conference, Trans. ASME, pp. 263–270.
Hoffmeister, H. W., Gente, A., and Weber, T. H., 1999, “Chip Formation at Titanium Alloys under Cutting Speed of up to 100 m/s,” 2nd International Conference on High Speed Machining, edited by Schulz, H., Molinari, A., Dudzinski, D., PTW Darmstadt University, pp. 21–28.
Lee,  D., 1985, “The Effect of Cutting Speed on Chip Formation under Orthogonal Machining,” Int. J. Eng. Industry, 107, pp. 55–63.
Hastings,  W. F., Mathews,  P., and Oxley,  P. L. B., 1980, “A Machining Theory For Predicting Chip Geometry, Cutting Forces etc. from Material Properties and Cutting Conditions,” Proc. R. Soc. London, Ser. A, 371, pp. 569–587.
Komanduri, R., Flom, D. G., and Lee, M., 1984, “High Speed Machining,” edited by Komanduri, R., Subramanian, K., and Von Turkovich, B. F., ASME, pp. 15–36.
Findley,  W. N., and Reed,  R. M., 1963, “The Influence of Extreme Speeds and Rake Angles in Metal Cutting,” ASME J. Eng. Ind., 85(2), pp. 49–67.
Wallace,  P. W., and Boothroyd,  G., 1964, “Tool Forces and Tool–Chip Friction in Orthogonal Machining,” J. Mech. Eng. Sci., 6(1), pp. 74–87.
Mathew,  P., and Oxley,  P. L. B., 1982, “Predicting the Effects of Very High Cutting Speeds on Cutting Forces, etc.,” CIRP Ann., 31(1), pp. 49–52.
Bredendick F., 1959, Die Massenkräfte beim Zerspanvorgang. Werkstatt und Betrieb, Jahrg. 92, Heft 10, Carl Hanser Verlag, München, pp. 739–742.
Klocke,  F., Raedt,  H.-W., and Hoppe,  S., 2001, “2d-FEM simulation of the orthogonal high speed cutting process,” Mach. Sci. Technol., 5(3), pp. 323–340.
Salomon, C. J., 1931, “Process for the Machining of Metals of Similarly-Acting Materials When Being Worked by Cutting Tools,” German Patent No 523594.
Recht, R. F., 1984, “A Dynamic Analysis of High Speed Machining,” High Speed Machining, edited by Komanduri, R. et al., ASME, New York, pp. 83–93.
Sutter,  G., Faure,  L., Molinari,  A., Delime,  A., and Dudzinski,  D., 1997, “Experimental Analysis of Cutting Process and Chip Formation at High Speed Machining,” J. Phys. IV, 7, pp. C3–33—C3–38.
Tanaka, Y., Tsuwa, H., and Kitano, M., 1967, “Cutting Mechanism in Ultra-High-Speed Machining,” Trans. ASME, paper No 67-PROD-14.
Montgomery,  R. S., 1976, “Friction and Wear at High Sliding Speeds,” Wear, 36, pp. 275–298.

Figures

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Schematic description of the experimental setup
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Details of the tool holding fixture
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Cutting device on numerically controlled lathe
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Different forces in orthogonal cutting process
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Oscillograms from strain gauges located near the tools
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Real time photographs of chip formation for two cutting speeds VC. (a) VC=15 m/s; (b) VC=45 m/s
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Longitudinal (FC) and transverse (FT) cutting forces as a function of the cutting speed for medium carbon steel (42CrMo4), width of cut w=10 mm, depth of cut t1=0.2 mm, rake angle α=0 deg. (♦ ▪: NC lathe ⋄ □: Air gun setup)
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Longitudinal (FC) and transverse (FT) cutting forces as a function of the cutting speed for medium carbon steel (42CrMo4), width of cut w=10 mm, depth of cut t1=0.5 mm, rake angle α=0 deg. (♦ ▪: NC lathe ⋄ □: Air gun setup).
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Effect of the cutting speed on the longitudinal FCe and the transverse FTe edge forces
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The ratio Fctt1=0.5/0.5/Fctt1−0.2/0.2 as a function of the cutting speed for medium carbon steel (42CrMo4), width of cut w=10 mm, rake angle αt=0 deg
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Experimental evolution of friction coefficient at the tool–chip interface for a wide range of cutting speeds

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