Title: Recent advances in plasticity applications in metal machining: slip-line models for machining with rounded cutting edge restricted contact grooved tools

Authors: Xiqun Wang, I.S. Jawahir

Addresses: TechSolve, Inc, 6705 Steger Drive, Cincinnati, OH 45237, USA. ' UK Centre for Manufacturing, Department of Mechanical Engineering, University of Kentucky, USA

Abstract: This paper presents a summary of new findings on plasticity applications in metal machining, primarily covering the recent efforts on developing new slip-line models for machining with restricted contact grooved tools which involve a finite cutting edge radius. Extended application of the initially developed plane-strain, rigid-plastic slip-line fields to take account of strain, strain-rate and temperature effects is shown to provide non-unique solutions for machining with grooved tools which most commonly incorporate geometric features such as a restricted contact and a rounded cutting edge. Predictions of cutting forces, chip thickness, chip up-curl radius, temperatures and flow stresses at the primary shear zone and at the tool-chip interface, etc. are made for a range of input conditions in orthogonal machining. The practical impact of these new findings on tool-wear and cutting tool design are emphasised in this paper.

Keywords: machining; plasticity; slip-line models; restricted contact; rounded cutting edges; restricted contact tools; grooved tools; strain rate; temperature effects; tool wear; tool design; cutting forces; chip thickness; chip up-curl radius; temperature; flow stresses; primary shear zone; tool-chip interface; orthogonal machining.

DOI: 10.1504/IJMMM.2007.015471

International Journal of Machining and Machinability of Materials, 2007 Vol.2 No.3/4, pp.347 - 360

Published online: 19 Oct 2007 *

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