Prediction of shear angle for continuous orthogonal cutting using thermo-mechanical constants of work material and cutting conditions

2007 ◽  
Vol 182 (1-3) ◽  
pp. 167-173 ◽  
Author(s):  
Andrey Toropov ◽  
Sung-Lim Ko
Keyword(s):  
Orthogonal Cutting ◽  
Shear Angle ◽  
Cutting Conditions ◽  
Work Material

scholarly journals An Explanation of the Apparent Bridgman Effect in Merchant’s Orthogonal Cutting Results

1967 ◽  
Vol 89 (3) ◽  
pp. 549-555 ◽  
Author(s):  
P. L. B. Oxley ◽  
M. J. M. Welsh
Keyword(s):  
Shear Strength ◽  
Flow Stress ◽  
Strain Rate ◽  
Hydrostatic Stress ◽  
Orthogonal Cutting ◽  
Shear Angle ◽  
Experimental Results ◽  
Variable Flow ◽  
Rate Dependent ◽  
Work Material

In Merchant’s modified shear angle solution, it is assumed following Bridgman that the shear strength of the work material is a function of the hydrostatic stress. Although Merchant’s experimental results confirm the assumed relation, subsequent workers have failed to obtain such agreement. In this paper, it is shown that Merchant’s results can be explained independently of the Bridgman effect by considering the variable flow stress properties of the work material, which are strain-rate dependent.

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.

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.

Prediction of Adiabatic Shear Critical Cutting Conditions of hardened AISI 1045 Steel with Different Hardness

2013 ◽  
Vol 589-590 ◽  
pp. 134-139
Author(s):  
Guo He Li ◽  
Yu Jun Cai ◽  
Hou Jun Qi
Keyword(s):  
Model Building ◽  
Orthogonal Cutting ◽  
Adiabatic Shear ◽  
Cutting Conditions ◽  
Constitutive Relationship ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Relationship Of ◽  
1045 Steel ◽  
Cutting Experiments

A method for building the constitutive relationship based on the J-C model and hardness is presented through considering the influence of hardness on the yield strength and the tensile strength. A constitutive relationship of hardened AISI 1045 is built by this method and the adiabatic shear critical cutting conditions of three kinds of hardness AISI 1045 steel are prediction through a model building by the linear pertubation analysis which considering the influence of compression stress of the primary shear zone, the cutting conditions and the constitutive relationship. For proving the prediction results, some orthogonal cutting experiments are performed to get the critical cutting conditions of adiabatic shear. The comparison shows that the prediction results are consistent with that of experiments.

Finite Element Modeling of Orthogonal Cutting of Pyrolytic Carbon

2011 ◽  
Author(s):  
Gautam Salhotra ◽  
Vivek Bajpai ◽  
Ramesh K. Singh
Keyword(s):  
Finite Element ◽  
Transverse Isotropy ◽  
Orthogonal Cutting ◽  
Chip Morphology ◽  
Pyrolytic Carbon ◽  
Cutting Conditions ◽  
Prediction Errors ◽  
Machining Parameters ◽  
Machined Surface ◽  
Cutting Model

Engineered features on pyrolytic carbon (PyC) have been demonstrated as an approach to improve the flow hemodynamics of the cardiovascular implants. In addition, it also finds application in thermonuclear components. These micro/meso scale engineered features are required to be machined onto the PyC leaflet. However, being a layered anisotropic material and brittle in nature, its machining characteristics differ from plastically deformable isotropic materials. Consequently, this study is aimed at creating a finite element model to understand the mechanics of material removal in the plane of transverse isotropy (horizontally stacked laminae) of PyC. A layered model approach has been used to capture the interlaminar shearing and brittle fracture during machining. A cohesive element layer has been used between the chip layer and the machined surface layer. The chip layer and workpiece are connected through a cohesive layer. The model predicts cutting forces and the chip length for different cutting conditions. The orthogonal cutting model has been validated against experimental data for different cutting conditions for cutting and thrust forces. Parametric studies have also been performed to understand effect of machining parameters on machining responses. This model also predicts chip lengths which have also been compared with the actual chip morphology obtained from microgrooving experiments. The prediction errors for cutting force and chip length are within 20% and 33%, respectively.

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
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