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TECHNICAL PAPERS

Predictive Analytical and Thermal Modeling of Orthogonal Cutting Process—Part II: Effect of Tool Flank Wear on 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

1

To whom correspondence should be addressed.

J. Manuf. Sci. Eng 128(2), 445-453 (Sep 16, 2005) (9 pages) doi:10.1115/1.2162591 History: Received May 19, 2005; Revised September 16, 2005

In this paper, predictive modeling of cutting and ploughing forces, stress distributions on tool faces, and temperature distributions in the presence of tool flank wear are presented. The analytical and thermal modeling of orthogonal cutting that is introduced in Part I of the paper is extended for worn tool case in order to study the effect of flank wear on the predictions. Work material constitutive model based formulations of tool forces and stress distributions at tool rake and worn flank faces are utilized in calculating nonuniform heat intensities and heat partition ratios induced by shearing, tool-chip interface friction, and tool flank face-workpiece interface contacts. In order to model forces and stress distributions under the flank wear zone, a force model from Waldorf (1996) (“Shearing Ploughing, and Wear in Orthogonal Machining  ,” Ph.D. thesis, University of Illinois at Urbana-Champaign, IL) is adapted. Model is tested and validated for temperature and force predictions in machining of AISI 1045 steel and AL 6061-T6 aluminum.

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Copyright © 2006 by American Society of Mechanical Engineers
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Figures

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Figure 1

Forces acting on the shear plane, the rake, and on the worn faces of the tool

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Figure 4

Thermal modeling of primary heat source on the workpiece side

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Figure 3

Thermal modeling of rubbing heat source on the tool rake and flank faces

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Figure 5

Thermal modeling of rubbing heat source on the workpiece side

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Figure 6

Predicted temperature distributions for AISI-1045 steel (a) 0.15mm and (b) 0.32mm of flank wear

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Figure 13

Temperature distributions in the chip, tool, and workpiece with the nonlinear heat partition ratio assumption for VB=0.32mm for AISI-1045 steel

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Figure 14

Influence of the tool flank wear on tool forces for AL-6061 T6 aluminum

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Figure 12

(a) Heat partition ratio along the tool-chip interface, (b) heat partition ratio along the tool-workpiece interface for AISI-1045 steel

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Figure 11

(a) Temperature distributions along the tool-chip interface, (b) temperature distributions along the tool-workpiece interface for AISI 1045 steel

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Figure 10

Influence of tool flank wear on the shear angle

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Figure 9

Change in the maximum temperatures with increasing flank wear for AISI-1045 steel

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Figure 8

Change in the heat partition coefficients B1 and B2 with increasing flank wear for (a) AISI-1045 and (b) AL 6061-T6

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Figure 7

Predicted temperature distributions for AL-6061 T6 for (a) 0.15 and (b) 0.25mm of flank wear

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Figure 2

(a) Heat sources in worn tool thermal modeling and (b) coordinate systems for chip, tool, and workpiece

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