A study of shear angle relationships in shearing process on the shear plane and the rake face in orthogonal cutting

KSME Journal ◽  
1995 ◽  
Vol 9 (3) ◽  
pp. 385-391 ◽  
Author(s):  
Man-Sung Choi
Keyword(s):  
Orthogonal Cutting ◽  
Shear Plane ◽  
Shear Angle ◽  
Rake Face

Governing Equations of the Shear Angle Oscillation in Dynamic Orthogonal Cutting

1986 ◽  
Vol 108 (4) ◽  
pp. 280-287 ◽  
Author(s):  
D. William Wu
Keyword(s):  
Orthogonal Cutting ◽  
Shear Plane ◽  
Shear Angle ◽  
Governing Equations ◽  
Line Field ◽  
Angle Variation ◽  
Wide Range ◽  
Theoretical Predictions ◽  
Transfer Behavior ◽  
Good Agreement

Chatter is a complex physical process in machining. One of the practical ways of modeling its transfer behavior is to derive the force functions theoretically from the substance of steady state cutting. This often requires a knowledge about the shear angle variation during the process. This paper presents a new method of modeling the angular oscillation in dynamic orthogonal cutting. The system governing equations were derived based on the work-hardening slip-line field theory in cutting mechanics by taking into account the changes of stress conditions on both the shear plane and the tool-chip interface. The result of a simulation study conducted for a wide range of cutting conditions has shown a very good agreement between the theoretical predictions and the existing experimental evidence.

Formation and Simulation of Cutting-Direction Burr in Orthogonal Cutting

2007 ◽  
Vol 24-25 ◽  
pp. 249-254 ◽  
Author(s):  
Hai Jun Qu ◽  
Gui Cheng Wang ◽  
Hong Jie Pei ◽  
Qin Feng Li ◽  
Yun Ming Zhu
Keyword(s):  
Shear Zone ◽  
Formation Process ◽  
Orthogonal Cutting ◽  
Shear Angle ◽  
Burr Formation ◽  
Size And Shape ◽  
Study Results ◽  
Edge Quality ◽  
And Performance ◽  
Cutting Direction

The cutting-direction burr is one of the important factors that influence the edge quality and performance of precision parts. The cutting-direction burr formation process is simulated with DeformTH3D. The mechanism of cutting-direction burr formation is analyzed in terms of the results of the simulation. The negative shear zone and initiation negative shear angle are discussed too. Study results show that the deformation of CDE is an important factor affect the cutting direction burrs’ size and shape.

The Effect of Material Flow Stress on Analytical Simulation of Machining

2010 ◽  
Vol 29-32 ◽  
pp. 1809-1814
Author(s):  
Bing Lin Li ◽  
Ling Ling ◽  
Yu Jin Hu ◽  
Xue Lin Wang
Keyword(s):  
Flow Stress ◽  
Shear Zone ◽  
Analytical Model ◽  
Material Flow ◽  
Model Simulation ◽  
Orthogonal Cutting ◽  
Shear Plane ◽  
Thermomechanical Model ◽  
Workpiece Material ◽  
Flow Stress Data

The flow stress data of the workpiece are extremely crucial for the cutting simulation. The study shows how the input data affect the analytical predictions of cutting force and temperature. The Johnson-Cook material model is used to represent workpiece flow stress in the primary shear zone. A thermomechanical model of orthogonal cutting is proposed based on the main shear plane divides the primary shear zone into two unequal parts. Five different sets of workpiece material flow stress data used in the Johnson-Cook’s constitutive equation are chosen and make the sensitivity analysis for analytical model. Simulation results were compared to orthogonal cutting test data from the available literature, and find the effects of flow stress on analytical model was different from that for finite element model.

Cyclic shear angle for lamellar chip formation in ultra-precision machining

2020 ◽  
Vol 234 (13) ◽  
pp. 2673-2680 ◽  
Author(s):  
Shaojian Zhang ◽  
Pan Guo ◽  
Zhiwen Xiong ◽  
Suet To
Keyword(s):  
Chip Formation ◽  
Diamond Tool ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Shear Angle ◽  
Precision Machining ◽  
Cyclic Shear ◽  
Intrinsic Mechanism ◽  
Classical Models ◽  
Ultra Precision

Shear angle is classically considered constant. In the study, a series of straight orthogonal cutting tests of ultra-precision machining revealed that shear angle cyclically evolved with each lamellar chip formation, i.e. cyclic shear angle. It grew up from an initial shear angle of 0° to a final shear angle 90°- α ( α: tool rake angle) and underwent a series of transient shear angles like classical shear angles and a critical shear angle. The critical shear angle is the sum of the half of the tool rake angle and the characteristic shear angle determined by material anisotropy without the friction effect. Moreover, a new model was developed. Further, a series of face turning tests of ultra-precision machining verified that the cyclic shear angle was the intrinsic mechanism of cyclic cutting forces and lamellar chip formation to induce twin-peak high-frequency multimode diamond-tool-tip vibration. Significantly, the study draws up an understanding of shear angle for the discrepancy among the classical models.

scholarly journals Experimental investigation of the shear angle variation during orthogonal cutting

2018 ◽  
Vol 5 (13) ◽  
pp. 26495-26500 ◽  
Author(s):  
Szabolcs Berezvai ◽  
Tamas G. Molnar ◽  
Daniel Bachrathy ◽  
Gabor Stepan
Keyword(s):  
Experimental Investigation ◽  
Orthogonal Cutting ◽  
Shear Angle ◽  
Angle Variation

Crystal anisotropy-dependent shear angle variation in orthogonal cutting of single crystalline copper

2020 ◽  
Vol 63 ◽  
pp. 41-48 ◽  
Author(s):  
Zhanfeng Wang ◽  
Junjie Zhang ◽  
Zongwei Xu ◽  
Jianguo Zhang ◽  
Guo Li ◽  
...  
Keyword(s):  
Orthogonal Cutting ◽  
Shear Angle ◽  
Angle Variation ◽  
Single Crystalline ◽  
Crystal Anisotropy

A Methodology to Determine Work Material Flow Stress and Tool-Chip Interfacial Friction Properties by Using Analysis of Machining

2004 ◽  
Author(s):  
Tug˘rul O¨zel ◽  
Erol Zeren
Keyword(s):  
Flow Stress ◽  
Material Flow ◽  
Orthogonal Cutting ◽  
Material Model ◽  
Interfacial Friction ◽  
Frictional Stress ◽  
Rake Face ◽  
Friction Characteristics ◽  
Work Material ◽  
1045 Steel

In this paper, we develop a methodology to determine flow stress at the machining regimes and friction characteristics at the tool-chip interface from the results of orthogonal cutting tests. We utilize metal cutting analysis originally developed by late Oxley and present some improvements. We also evaluate several temperature models in calculating the average temperatures at primary and secondary deformation zones and present comparisons with the experimental data obtained for AISI 1045 steel through assessment of machining models (AMM) activity. The proposed methodology utilizes measured forces and chip thickness obtained through a basic orthogonal cutting test. We conveniently determine work material flow stress at the primary deformation zone and the interfacial friction characteristics along tool rake face. Calculated friction characteristics include parameters of the normal and frictional stress distributions on the rake face. Determined flow stress data from orthogonal cutting tests is combined with the flow stress measured through split-hopkinson pressure bar (SHPB) tests and the Johnson-Cook work material model is obtained. Therefore, with this methodology, we extend the applicability of Johnson-Cook work material model to machining regimes.

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