Predictive Analytical and Thermal Modeling of Orthogonal Cutting Process—Part I: Predictions of Tool Forces, Stresses, and Temperature Distributions

[+] Author and Article Information
Yiğit Karpat

Department of Industrial and Systems Engineering, Rutgers University, Piscataway, NJ 08854

Tuğrul Özel1

Department of Industrial and Systems Engineering, Rutgers University, Piscataway, NJ 08854ozel@rci.rutgers.edu


To whom correspondence should be addressed.

J. Manuf. Sci. Eng 128(2), 435-444 (Sep 16, 2005) (10 pages) doi:10.1115/1.2162590 History: Received May 19, 2005; Revised September 16, 2005

In this paper, a predictive thermal and analytical modeling approach for orthogonal cutting process is introduced to conveniently calculate forces, stress, and temperature distributions. The modeling approach is based on the work material constitutive model, which depends on strain, strain rate, and temperature. In thermal modeling, oblique moving band heat source theory is utilized and analytically combined with modified Oxley’s parallel shear zone theory. Normal stress distribution on the tool rake face is modeled as nonuniform with a power-law relationship. Hence, nonuniform heat intensity at the tool-chip interface is obtained from the predicted stress distributions utilizing slip line field analysis of the modified secondary shear zone. Heat sources from shearing in the primary zone and friction at the tool-chip interface are combined, heat partition ratios are determined for temperature equilibrium to obtain temperature distributions depending on cutting conditions. Model validation is performed by comparing some experimental results with the predictions for machining of AISI 1045 steel, AL 6082-T6, and AL 6061-T6 aluminum. Close agreements with the experiments are observed. A set of detailed, analytically computed stress and temperature distributions is presented.

Copyright © 2006 by American Society of Mechanical Engineers
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Figure 1

Oblique moving band heat source in an infinite medium

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Figure 2

Modified Hahn’s model for an oblique band heat source in a semi-infinite medium

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Figure 3

Heat transfer model for the frictional heat source at the tool-chip interface (a) on the chip side as a moving band heat source (b) on the tool side as a stationary rectangular heat source

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Figure 4

Common coordinate system for combined effect heat sources

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Figure 5

Heat intensity model along the rake face of the tool

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Figure 6

Simplified deformation zones in orthogonal cutting

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Figure 7

Forces acting on the shear plane and the tool with resultant stress distributions on the tool rake face

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Figure 8

Flow chart for computing average temperatures

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Figure 9

Flow chart of the computational algorithm

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Figure 10

Comparison of the predictions of the cutting force (a), and thrust force (b) with experimental data from (23)

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Figure 11

Predicted stress distributions on the tool rake face for machining AISI 1045 steel

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Figure 12

Temperature distributions for AISI 1045 at conditions in test 1. (The figure is drawn perpendicular to the tool-chip interface for simplicity; the figure should be rotated 7deg clockwise for actual view.)

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Figure 13

Temperatures along the tool-chip interface for test condition 1 for AISI 1045

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Figure 14

Heat partition ratio along the tool chip interface for test condition 1 for AISI 1045

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Figure 15

Temperature distributions in the chip for Al 6082-T6 at conditions in test 2

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Figure 16

Temperature distributions in the chip for Al 6061-T6 at conditions in test 3





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