This paper develops a new analytical model to predict the chip back-flow angle in machining with restricted contact grooved tools. The model is derived from a recently established universal slip-line model for machining with restricted contact cutaway tools. A comprehensive definition of the chip back-flow angle is presented first, and based on this, a quantitative analysis of the chip back-flow effect is established for a given set of cutting conditions, tool geometry, and variable tool-chip interfacial stress state. The model also predicts the cutting forces, the chip thickness, and the chip up-curl radius. A full experimental validation of the analytical predictive model involving the use of high speed filming technique is then presented for the chip back-flow angle. This validation provides a range of feasible/prevalent tool-chip interfacial frictional conditions for the given set of input conditions.
Issue Section:
Technical Papers
1.
Chao
, B. T.
, and Trigger
, K. J.
, 1959
, “Controlled Contact Cutting Tools
,” ASME J. Eng. Ind.
, 81
, pp. 139
–151
.2.
Oxley
, P. L. B.
, 1962
, “An Analysis for Orthogonal Cutting with Restricted Tool-Chip Contact
,” Int. J. Mech. Sci.
, 4
, pp. 129
–135
.3.
Lo
, S. Y.
, Lode
, U.
, and Armarego
, E. J. A.
, 1966
, “Experiments with Controlled Contact Tools
,” Int. J. Mach. Tool Des. Res.
, 6
, pp. 115
–127
.4.
Friedman
, M. Y.
, and Lenz
, E.
, 1970
, “Investigation of the Tool-Chip Contact Length in Metal Cutting
,” Int. J. Mach. Tool Des. Res.
, 10
, pp. 401
–416
.5.
Jawahir, I. S., 1986, “An Experimental and Theoretical Study of the Effects of Tool Restricted Contact on Chip Breaking,” Ph.D. Thesis, The University of New South Wales, Australia.
6.
Jawahir
, I. S.
, 1988
, “The Tool Restricted Contact Effect as a Major Influencing Factor in Chip Breaking: an Experimental Analysis
,” CIRP Ann.
, 37
, pp. 121
–126
.7.
Takeyama
, H.
, and Usui
, E.
, 1958
, “The Effect of Tool-Chip Contact Area in Metal Machining
,” Trans. ASME
, 80
, pp. 1089
–1096
.8.
Hoshi, K., and Usui, E., 1962, “Wear Characteristics of Carbide Tools with Artificially Controlled Tool-Chip Contact Length,” Proceedings of the 3rd International MTDR Conference, University of Birmingham, September, pp. 121–128.
9.
Usui
, E.
, and Shaw
, M. C.
, 1962
, “Free Machining Steel-IV: Tools with Reduced Contact Length
,” ASME J. Eng. Ind.
, 84
, pp. 89
–102
.10.
De Chiffre
, L.
, 1982
, “Cutting Tools with Restricted Contact
,” Int. J. Mach. Tool Des. Res.
, 22
, pp. 321
–331
.11.
Johnson
, W.
, 1962
, “Some Slip-Line Fields for Swaging or Expanding, Indenting, Extruding and Machining for Tools with Curved Dies
,” Int. J. Mech. Sci.
, 4
, pp. 323
–347
.12.
Usui
, E.
, and Hoshi
, K.
, 1963, “Slip-Line Fields in Metal Machining Which Involve Centered Fans,” International Research for Production Engineering, ASME, 61, pp. 61–67.13.
Kudo
, H.
, 1965
, “Some New Slip-Line Solutions for Two-Dimensional Steady-State Machining
,” Int. J. Mech. Sci.
, 7
, pp. 43
–55
.14.
Shi
, T.
, and Ramalingam
, S.
, 1993
, “Modeling Chip Formation With Grooved Tools
,” Int. J. Mech. Sci.
, 35
, pp. 741
–756
.15.
Childs
, T. H. C.
, 1980
, “Elastic Effects in Metal Cutting Chip Formation
,” Int. J. Mech. Sci.
, 22
, pp. 457
–466
.16.
Strenkowski
, J. S.
, and Athavale
, S. M.
, 1997
, “A Partially Constrained Eulerian Orthogonal Cutting Model for Chip Control Tool
,” ASME J. Manuf. Sci. Eng.
, 119
, pp. 681
–688
.17.
Athavale
, S. M.
, and Strenkowski
, J. S.
, 1997
, “Material Damage-Based Model for Predicting Chip Breakability
,” ASME J. Manuf. Sci. Eng.
, 119
, pp. 675
–680
.18.
Childs, T. H. C., Maekawa, K., Obikawa, T., and Yamane, Y., 2001, Metal Machining Theory and Applications, Arnold, London, United Kingdom.
19.
Dillon, O. W., and Zhang, H., 1999, “An Analysis of Cutting Using a Grooved Tool,” Proceedings of the 2nd CIRP International Workshop on Modeling of Machining Operations, Nantes, France, 25-26 January.
20.
Mittal
, R. N.
, and Juneja
, B. L.
, 1982
, “Effect of Stress Distribution on the Shear Angle in Controlled Contact Orthogonal Cutting
,” Int. J. Mach. Tool Des. Res.
, 22
, pp. 87
–96
.21.
Rubenstein
, C.
, 1968
, “The Mechanism of Orthogonal Cutting with Controlled Contact Tools
,” Int. J. Mach. Tool Des. Res.
, 8
, pp. 203
–216
.22.
Zhu
, R.
, Kapoor
, S. G.
, Devor
, R. E.
, and Athavale
, S. M.
, 1999
, “Mechanistic Force Models for Chip Control Tools
,” ASME J. Manuf. Sci. Eng.
, 121
, pp. 408
–416
.23.
Arsecularatne
, J. A.
, and Oxley
, P. L. B.
, 1997
, “Prediction of Cutting Forces in Machining with Restricted Contact Tools
,” Mach. Sci. Technol.
1
, pp. 95
–112
.24.
Worthington
, B.
, 1975
, “The Effect of Rake Face Configuration on the Curvature of the Chip in Metal Cutting
,” Int. J. Mach. Tool Des. Res.
, 15
, pp. 223
–239
.25.
Fang
, N.
, Jawahir
, I. S.
, and Oxley
, P. L. B.
, 2001
, “A Universal Slip-Line Model with Nonunique Solutions for Machining With Curled Chip Formation and a Restricted Contact Tool
,” Int. J. Mech. Sci.
, 43
, pp. 557
–580
.26.
Dewhurst
, P.
, 1978
, “On the Non-Uniqueness of the Machining Process
,” Proc. R. Soc. London, Ser A
, 360
, pp. 587
–610
.27.
Lee
, E. H.
, and Shaffer
, B. W.
, 1951
, “The Theory of Plasticity Applied to a Problem of Machining
,” Trans. ASME
, 18
, pp. 405
–413
.28.
Merchant
, M. E.
, 1944
, “Basic Mechanics of the Metal Cutting Process
,” Trans. ASME
, 66
, pp. A168–A175
A168–A175
.29.
Dewhurst
, P.
, 1979
, “The Effect of Chip Breaker Constraints on the Mechanics of the Machining Process
,” CIRP Ann.
, 28
, pp. 1
–5
.30.
Green
, A. P.
, 1954
, “On the Use of Hodographs in Problems of Plane Plastic Strain
,” J. Mech. Phys. Solids
, 2
, pp. 73
–80
.31.
Hill, R., 1998, The Mathematical Theory of Plasticity, Oxford University Press, Oxford, United Kingdom.
32.
Johnson, W., Sowerby, R., and Haddow, J. B., 1970, Plane-Strain Slip-Line Field: Theory and Bibliography, American Elsevier Publishing Company, Inc., New York.
33.
Oxley, P. L. B., 1989, The Mechanics of Machining: An Analytical Approach to Assessing Machinability, Ellis Horwood Limited, Chichester, United Kingdom.
34.
Fang
, N.
, and Jawahir
, I. S.
, 2002
, “An Analytical Predictive Model and Experimental Validation for Machining with Grooved Tools Incorporating the Effects of Strains, Strain-Rates, and Temperatures
,” CIRP Ann.
, 51
, pp. 83
–86
.35.
Shih
, A. J.
, 1996
, “Finite Element Analysis of the Rake Angle Effects on Orthogonal Metal Cutting
,” Int. J. Mech. Sci.
, 38
, pp. 1
–17
.36.
Ozel
, T.
, and Taylan
, A.
, 2000
, “Determination of Workpiece Flow Stress and Friction at the Chip-Tool Contact for High Speed Cutting
,” International Journal of Machine Tools and Manufacture
, 40
, pp. 133
–152
.37.
Fang
, N.
, and Jawahir
, I. S.
, 2002
, “Analytical Predictions and Experimental Validation of Cutting Forces, Chip Thickness, and Chip Back-Flow Angle in Restricted Contact Machining Using the Universal Slip-Line Model
,” International Journal of Machine Tools and Manufacture
, 42
, pp. 681
–694
.38.
Fang
, N.
, 2003
, “Machining with Tool-Chip Contact on the Tool Secondary Rake Face—Part I: A New Slip-Line Model
,” Int. J. Mech. Sci.
, 44
, pp. 2337
–2354
.39.
Fang
, N.
, 2003
, “Machining with Tool-Chip Contact on the Tool Secondary Rake Face—Part II: Analysis and Discussion
,” Int. J. Mech. Sci.
, 44
, pp. 2355
–2368
.40.
Dewhurst
, P.
, and Collins
, I. F.
, 1973
, “A Matrix Technique Constructing Slip-Line Field Solutions to a Class of Plane Strain Plasticity Problems
,” Int. J. Numer. Methods Eng.
, 7
, pp. 357
–378
.41.
Powell, M. J. D., 1970, “A Fortran Subroutine for Solving Systems of Non-Linear Algebraic Equations,” in Rabinpwitz, 1970, Numerical Methods for Nonlinear Algebraic Equations, Gordon and Breach, London, United Kingdom.
42.
Hill
, R.
, 1954
, “The Mechanics of Machining: A New Approach
,” J. Mech. Phys. Solids
, 3
, pp. 47
–53
.43.
Fang
, N.
, and Jawahir
, I. S.
, 2001
, “A New Methodology for Determining the Stress State of the Plastic Region in Machining with Restricted Contact Tools
,” Int. J. Mech. Sci.
, 43
, pp. 1747
–1770
.44.
Fang
, N.
, and Jawahir
, I. S.
, 2000, “Prediction and Validation of Chip Up-Curl in Machining Using the Universal Slip-Line Model,” Transaction of the NAMRC, 28, pp. 137–142.Copyright © 2003
by ASME
You do not currently have access to this content.
