Abstract
Metal cutting is a complex process in which several mechanisms are at work simultaneously. The mathematical modelling allows carrying out research into the optimization of machining conditions. This work examines the simulation of chip formation during the process of cutting. The studies demonstrated that the chip formation process, taking into account the plastic deformation and destruction of metal in the local zone, is most appropriately represented by a rheological model in the form of a series connection of elasticductile- plastic relaxing medium of Ishlinskiy (reflecting the process of primary deformation of metal from the cut off layer) and the medium of Voigt with two elastic-dissipative elements (representing the process of deformation and frictions from the convergent shaving). The attained complex rheological model served as the basis for constructing a representative dynamic model for the chip formation process. The key factors that govern the chip formation have been taken into account, such as tool vibration frequency and amplitude, depth of cut, feed rate.
Highlights
The process of chip formation proceeds in a relatively small area with a high strain rate, with a very low relative deformation of the material [1, 2]
The studies demonstrated that the chip formation process, taking into account the plastic deformation and destruction of metal in the local zone, is most appropriately represented by a rheological model in the form of a series connection of elasticductile-plastic relaxing medium of Ishlinskiy and the medium of Voigt with two elastic-dissipative elements
± (β2c1 + β2c3 + β3c1 + β3c2)2 − 4β2β3(c1c2 + c2c3 + c1c3). It follows from proposed rheological model in the zone of primary plastic deformation occur processes which generate instability of chip formation
Summary
The process of chip formation proceeds in a relatively small area with a high strain rate, with a very low relative deformation of the material [1, 2]. Many real metals combine behaviours of all these elements and it is possible to consider the stressstrain state of metal under the action of external loads. Maxwell and Voigt models [3] are adequate for qualitative analyses, but generally poor for the representation of behaviour of real materials. Our model is constructed in two stage up to the moment of the formation of chip, i.e. the deformation to the shear plane and the shift of the thin stripe of metal on the plane of shift
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