Metal Cutting Mechanics

Metal Cutting Mechanics outlines the fundamentals of metal cutting analysis, reducing the extent of empirical approaches to the problems as well as bridging the gap between design and manufacture. The author distinguishes his work from other works through these aspects:· considering the system engineering of the cutting process· identifying the singularity of the cutting process among other closely related manufacturing processes by chip formation, caused by bending and shear stresses in the deformation zone· suggesting a distinctive way toward predictability of the metal cutting process· devoting special attention to experimental methodologyMetal Cutting Mechanics provides an exceptional balance between general reading and research analysis, presenting industrial and academic requirements in terms of basic scientific factors as well as application potential.

Introduction

1

(10)

General

1

(1)

Reasons for studying metal cutting

2

(1)

History of metal cutting

3

(3)

Basic problems requiring solution

6

(5)

References

8

(3)

System approach

11

(62)

Observation part of existing studies on chip formation

12

(3)

System and assemblage

15

(11)

Mathematical definition of system

15

(5)

Mathematical definition of an assemblage

20

(1)

The relation between a system and an assemblage

21

(5)

Cutting system

26

(47)

First step: time dependence of parameters of cutting system and their dynamic interactions

26

(1)

First stage: observational part

26

(7)

Second stage: experimental verification

33

(6)

Third stage: quantitative analysis of the bending stress

39

(5)

Definition of the metal cutting process

44

(1)

Difficulties due to high ductility of workpiece material

45

(2)

Model of chip formation when seizure occurs at tool-chip interface

47

(4)

Generalized model of chip formation and structure classification

51

(4)

Second step: controllability of the cutting system

55

(6)

Principle of control of the cutting system

61

(8)

References

69

(4)

Parallel-sided deformation zone theory

73

(54)

The role of engineering plasticity in metal cutting studies

73

(6)

Velocity diagram: what seems to be the problem?

79

(2)

Role of the velocity diagram in the theory of metal cutting

81

(1)

The discontinuity of the tangential velocity

82

(6)

Real velocity diagram in metal cutting

88

(6)

Velocity diagram at the second stage

88

(6)

Velocity diagram at the third stage

94

(1)

Real virtual work equation

94

(1)

Analysis of plastic deformation in metal cutting

95

(22)

Chip compression ratio and strain --- what is a real measure of plastic deformation in metal cutting?

95

(3)

Infinitesimal strain

98

(4)

The rotational element

102

(3)

Infinitesimal strain of a line element

105

(1)

Strain compatibility equation

106

(2)

Finite displacement of a point in a continuous body

108

(1)

Finite strain

109

(2)

Principal strains and strain invariants

111

(2)

Increments in the strain components

113

(1)

Strain in metal cutting

114

(3)

Strain rate in metal cutting

117

(10)

Reported strain rates

117

(2)

Critical analysis of the reported strain rates

119

(2)

Strain rate tensor

121

(2)

References

123

(4)

Work material considerations

127

(56)

What has to be predicted according to existing theories?

128

(1)

Review of attempts made to predict shear flow stress

129

(3)

The first approach

130

(1)

The second approach

131

(1)

The third approach

132

(1)

What has to be predicted in reality?

132

(2)

Experimental verification

134

(7)

Incremental compression

134

(2)

Metal cutting

136

(1)

Influence of high temperatures

137

(4)

The cause of significant discrepancies in reported results

141

(2)

Nature of plastic deformation of polycrystalline materials

143

(13)

Fracture and its correlation with deformation

143

(2)

Plasticity and stress relaxation

145

(2)

Defect population in metals

147

(3)

Influence of the state of stress

150

(4)

Generalizations

154

(2)

Fracture of ductile polycrystallines

156

(1)

Mechanism of fracture in metal cutting

156

(11)

Possible regions of fracture

157

(1)

Experimental evidence

158

(5)

Type of fracture

163

(4)

Fracture strain determination

167

(16)

Existent criteria of ductile fracture

169

(2)

Basic starting concepts for the analysis of ductile fracture

171

(3)

Relationship between strain at fracture of a material and parameters of current plastic deformation

174

(4)

References

178

(5)

Finite element simulation

183

(30)

General

183

(1)

FEM in metal cutting

183

(1)

Aims and layout

184

(1)

Computational details of simulation

184

(5)

Program structure

185

(2)

Workpiece and tool materials modeling

187

(2)

Applications of FEM

189

(2)

Results and discussion

191

(13)

Modeling of the deformation zone

192

(5)

Modeling of the tool/chip interface

197

(1)

Known results

197

(1)

Simulation of stress distribution at tool/chip interface

198

(1)

Shear stress distribution

198

(1)

Normal stress distribution

199

(3)

Contact processes at the tool/chip interface

202

(2)

Comparison with machining experiments

204

(9)

References

210

(3)

Methodology of experimental studies in metal cutting

213

(58)

Similarity methods in metal cutting

213

(32)

General

213

(2)

Basics of similarity

215

(3)

Applications in metal cutting studies

218

(1)

Optimum cutting temperature---Makarow's law

218

(9)

Similarity numbers

227

(2)

Use of similarity numbers in metal cutting

229

(1)

Energy balance

229

(5)

Optimum cutting speed and machinability

234

(4)

Quality of the machined surface and tool wear

238

(7)

Temperature measurements in metal cutting

245

(10)

Conventional thermocouples

245

(4)

Tool-work (natural) thermocouple

249

(4)

Semi-artificial and running thermocouples

253

(2)

Cutting force measurements

255

(16)

General

255

(2)

Procedure used in the current study

257

(10)

References

267

(4)

Appendix. Cutting tool geometry

271

(18)

A.1 Tool-in-hand system

271

(5)

A.1.1 Planes

271

(1)

A.1.2 Angles

272

(4)

A.2 Tool-in-machine system (setting system)

276

(3)

A.3 Tool-in-use system

279

(4)

A.4 Determination of the uncut chip cross-section for non-free and non-orthogonal cutting conditions

283

(6)

References

287

(2)

Index

289

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Metal Cutting Mechanics

Summary

Table of Contents

Supplemental Materials