A hybrid model for analysis of 3-D machining operations

Abstract

This paper describes the development of a physically based model for the analysis of commonly encountered 3-D machining processes using arbitrarily oriented cutting tools. This model consists of two modules, a generalized upper bound analysis module capable of handling any given cutting edge geometry, and a 2-D machining analysis module capable of using a wide range of constitutive equations to handle most commonly machined materials. The upper bound module is used for prediction of the chip flow angle and is followed by application of the extended Oxley's analysis of machining (Adibi-Sedeh, Madhavan, and Bahr 2003a) in the equivalent plane to obtain two components of the cutting force in the plane. The out-of-plane component is calculated by applying the constraint that the resultant cutting force should not have any component along the rake face in a direction perpendicular to the chip flow direction. The performance of the hybrid model is validated through extensive comparison with experimental data for different operations and materials.