Abstract
The global aim of this paper is to propose a complete analytical model concerning the material removal. In order to take into account all the aspects of the process, a “phenomena split approach”, based on the assumption that the material removal is the summation of three major contributions, ploughing, spring back and “pure cut” was adopted. This new methodology is developed on the base of experimental tests and industrial experience. In fact the chip is not systematically present. When the chip exists, a part of theoretical layer of the material to be removed is transformed in lateral burrs and elastic compression under the tool tip. In this paper this new approach is presented and the “pure cut” contribution is developed in details. This analytical sub-model of chip formation is calibrated and fitted with a finite element modeling, in order to presents new hypothesis and new formula based on the physics close to the tip of the tool. The chip is considered rigid and uniform, and the regime is supposed stationary. Thermo-mechanical law is applied in shear zones where plastic strain, temperature and strain rate are concentrated. The model takes into account the cutting edge radius too, using an equivalent cutting angle. The friction coefficient at the interface tool-chip is also analytically computed and the present model is considered predictive.DOI: http://dx.doi.org/10.5755/j01.mech.18.6.3161
Highlights
Cutting processes are widely used in different industries to cut various engineering parts
The cutting tool removes a specific layer of work material (Fig. 11). f is the theoretical uncut thicknesses to remove with the tool, R is the cutting edge radius, f - fcr the real layer of work material removed
In this paper an analytical model of material removal is presented. This model is based on the new assumption that cutting operation can be defined as a sum of three contributions: ploughing, spring back and pure cut
Summary
Orthogonal cutting represented by a 2D model is considered in the present study. The cutting tool removes a specific layer of work material (Fig. 11). f is the theoretical uncut thicknesses to remove with the tool, R is the cutting edge radius, f - fcr the real layer of work material removed. The cutting tool removes a specific layer of work material (Fig. 11). F is the theoretical uncut thicknesses to remove with the tool, R is the cutting edge radius, f - fcr the real layer of work material removed. For low values of the f/R ratio (f < fcr) the chip formation does not occur; only spring back and ploughing appear (in case of 3D approach). The chip formation is only possible if f is greater than fcr: in this case it is supposed that the cutting process is made with a virtual tool, with a cutting edge radius R = 0 (Fig. 11), and the effective layer work material removed is f - fcr. In the proposed approach the ploughing and spring back phenomena are caused by the cutting radius and, if it is zero, only the pure cutting condition will exist. The effects of the cutting radius exists in ”pure cutting case” too; it will be explained
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