It is well known that the edge geometry of a cutting tool affects the forces measured in metal cutting. Two experimental methods have been suggested in the past to extract the ploughing (noncutting) component from the total measured force: (1) the extrapolation approach and (2) the dwell force technique. This study reports the behavior of zinc during orthogonal machining using tools of controlled edge radius. Application of both the extrapolation and dwell approaches showed that neither produces an analysis that yields a material response consistent with the known behavior of zinc. Further analysis shows that the edge geometry modifies the shear zone of the material and thereby modifies the forces. When analyzed this way, the measured force data yield the expected material response without requiring recourse to an additional ploughing component.
Issue Section:
Technical Papers
1.
Merchant
, M. E.
, 1945
, “Mechanics of the Metal Cutting Process: I-Orthogonal Cutting and the Type 2 Chip
,” J. Appl. Phys.
, 16
, pp. 267
–275
.2.
Backer
, W. R.
, Marshall
, E. R.
, and Shaw
, M. C.
, 1952
, “The Size Effect in Metal Cutting
,” Trans. ASME
, 74
, pp. 61
–72
.3.
Thomsen
, E. G.
, Lapsley
, J. T.
, and Grassi
, R. C.
, 1953
, “Deformation Work Absorbed by the Workpiece During Metal Cutting
,” Trans. ASME
, 75
, pp. 591
–603
.4.
Masuko
, M.
, 1953
, “Fundamental Research on Metal Cutting (1st Report), A New Analysis of Cutting Forces
,” Trans. Jpn. Soc. Mech. Eng.
, 19
, pp. 32
–39
.5.
Albrecht
, P.
, 1960
, “New Developments in the Theory of Metal Cutting Process: Part I-The Ploughing Process in Metal Cutting
,” ASME J. Eng. Ind.
, 82
, pp. 348
–357
.6.
Albrecht
, P.
, 1961
, “New Developments in the Theory of Metal Cutting Process: Part II-The Theory of Chip Formation
,” ASME J. Eng. Ind.
, 83
, pp. 557
–568
.7.
Connolly
, R.
, and Rubenstein
, C.
, 1968
, “The Mechanics of Continuous Chip Formation in Orthogonal Cutting
,” Int. J. Mach. Tool Des. Res.
, 8
, pp. 159
–187
.8.
Wu
, D. W.
, 1988
, “Application of a Comprehensive Dynamic Cutting Force Model to Orthogonal Wave Generating Processes
,” Int. J. Mech. Sci.
, 30
, pp. 581
–600
.9.
Endres
, W. J.
, Devor
, R. E.
, and Kapoor
, S. G.
, 1995
, “A Dual Mechanism Approach to the Prediction of Machining Forces-Parts I & 2
,” ASME J. Eng. Ind.
, 117
, pp. 526
–542
.10.
Waldorf, D. J., 1996, “Shearing, Ploughing and Wear in Orthogonal Machining,” Ph.D. Thesis, University of Illinois at Urbana-Champaign.
11.
Abebe
, M.
, and Appl
, F. C.
, 1981
, “A Slip-Line Solution for Negative Rake Angle Cutting
,” Proc., NAMRC
, 19
, pp. 341
–348
.12.
Stevenson
, R.
, 1998
, “The Measurement of Parasitic Forces in Orthogonal Cutting
,” Int. J. Mach. Tools Manuf.
, 38
, pp. 113
–130
.13.
Stevenson
, R.
, and Stephenson
, D. A.
, 1995
, “The Mechanical Behavior of Zinc During Machining
,” ASME J. Eng. Ind.
, 117
, pp. 172
–178
.14.
Stevenson
, R.
, 1999
, “A Reassessment of the Extrapolation Technique for Determining the Parasitic Cutting Loads under Orthogonal Cutting in Strain Rate Hardening Materials
,” Mach. Sci. Technol.
, 3
, pp. 1
1
.15.
Colwell
, L. V.
, 1971
, “Methods for Sensing the Rate of Tool Wear
,” CIRP Ann.
, 19
, pp. 647
647
.16.
Colwell, L. V., and Mazur, J. C., 1976, “Tool Wear Tracking in the Production Shop,” Proc., NAMRC, pp. 420.
17.
Schimmel
, R. J.
, Manjunathaiah
, J.
, and Endres
, W. J.
, 2000
, “An Experimental Investigation of the Variability of Edge Hones and Their Effects on Machining Forces
,” ASME J. Manuf. Sci. Eng.
, 122
, pp. 590
–593
.18.
Stevenson
, R.
, and Stephenson
, D. A.
, 1996
, “The Effect of Prior Cutting Conditions on the Shear Mechanics of Orthogonal Machining
,” ASME J. Manuf. Sci. Eng.
, 120
, pp. 13
–20
.19.
Oxley, P. L. B., 1989, The Mechanics of Machining: An Analytical Approach to Assessing Machinability, Ellis Horwood Limited, Chichester.
20.
Wagoner
, R. H.
, 1981
, “A Technique for Measuring Strain Rate Sensitivity
,” Metall. Trans. A
, 12A
, pp. 71
–75
.21.
Manjunathaiah, J., and Endres, W. J., 1996, “Effects of a Honed Cutting Edge in Machining,” Proc., Second S. M. Wu Symp. on Mfg. Sci., pp. 25–30.
22.
Manjunathaiah
, J.
, and Endres
, W. J.
, 2000
, “A Study of Apparent Negative Rake Angle and its Effects on Shear Angle During Orthogonal Cutting with Edge-Radiused Tools
,” Trans. NAMRI/SME
, 28
, pp. 197
–202
.23.
Nakayama
, K.
, and Tamura
, K.
, 1968
, “Size Effect in Metal Cutting Force
,” ASME J. Eng. Ind.
, 90
, pp. 119
–126
.24.
Kececioglu
, D.
, 1958
, “Shear-Strain Rate in Metal Cutting and its Effects on Shear-Flow Stress
,” Trans. ASME
, 80
, pp. 158
–168
.Copyright © 2002
by ASME
You do not currently have access to this content.
