Application of Finite Deformation Theory to the Development of an Orthogonal Cutting Model—Part II: Experimental Investigation and Model Validation

Yuliu Zheng; Xuefei Hu; John W. Sutherland

doi:10.1115/1.2193556

Journal of Manufacturing Science and Engineering | Volume 128 | Issue 3 | TECHNICAL PAPERS

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TECHNICAL PAPERS

Application of Finite Deformation Theory to the Development of an Orthogonal Cutting Model—Part II: Experimental Investigation and Model Validation

Yuliu Zheng, Xuefei Hu and John W. Sutherland

[+] Author and Article Information

Yuliu Zheng¹

Department of Mechanical Engineering–Engineering Mechanics, Michigan Technological University, Houghton, MI 49931-1295

Xuefei Hu²

Department of Mechanical Engineering–Engineering Mechanics, Michigan Technological University, Houghton, MI 49931-1295

John W. Sutherland

Department of Mechanical Engineering–Engineering Mechanics, Michigan Technological University, Houghton, MI 49931-1295

Presently at Manufacturing R&D, Federal Mogul Corporation.

Presently at Global Engine Development-NA, Engine Systems, Caterpillar, Inc.

J. Manuf. Sci. Eng 128(3), 767-774 (Nov 14, 2005) (8 pages) doi:10.1115/1.2193556 History: Received January 06, 2005; Revised November 14, 2005

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Abstract

In Part 1 of this paper, a continuum mechanics model of the orthogonal cutting process was developed based on finite deformation theory. In this part of the paper, constitutive equations for O1 and L6 tool steels are developed using the results from split Hopkinson pressure bar tests. Statistically designed orthogonal cutting experiments are conducted to secure process results across a range of cutting conditions. The continuum mechanics model established in Part 1 of this paper is used to simulate all the cutting tests. All the model outputs are calculated and compared with the corresponding cutting experiment results. Good agreement is observed between the model predictions and the experimental results. The continuum mechanics model is successfully used to predict the cutting force, shear angle, and temperature.

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Figure 1

Split Hopkinson pressure bar setup

Experimental and fitted constitutive equation behaviors for O1 and L6 tool steels

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Figure 2

Experimental and fitted constitutive equation behaviors for O1 and L6 tool steels

The extrapolated constitutive relationships for O1 and L6 steels

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Figure 3

The extrapolated constitutive relationships for O1 and L6 steels

The orthogonal cutting experimental setup

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Figure 4

The orthogonal cutting experimental setup

Cutting force comparison for O1 tool steel

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Figure 5

Cutting force comparison for O1 tool steel

Cutting force comparison for L6 tool steel

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Figure 6

Cutting force comparison for L6 tool steel

Thrust force comparison for O1 tool steel

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Figure 7

Thrust force comparison for O1 tool steel

Thrust force comparison for L6 tool steel

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Figure 8

Thrust force comparison for L6 tool steel

Shear angle comparisons for O1 tool steel

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Figure 9

Shear angle comparisons for O1 tool steel

Shear angle comparisons for L6 tool steel

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Figure 10

Shear angle comparisons for L6 tool steel

Temperature along a flowline at different cutting velocities

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Figure 11

Temperature along a flowline at different cutting velocities

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Zheng Y, Hu X, Sutherland JW. Application of Finite Deformation Theory to the Development of an Orthogonal Cutting Model—Part II: Experimental Investigation and Model Validation. ASME. J. Manuf. Sci. Eng. 2005;128(3):767-774. doi:10.1115/1.2193556.

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Application of Finite Deformation Theory to the Development of an Orthogonal Cutting Model—Part II: Experimental Investigation and Model Validation

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