scispace - formally typeset
Search or ask a question
Journal ArticleDOI

Temperatures in Orthogonal Metal Cutting

01 Jun 1963-Vol. 177, Iss: 1, pp 789-810
TL;DR: In this paper, the authors used a photographic technique for the determination of the complete temperature distribution in the orthogonal metal cutting process; they are found to disagree with previous theoretical predictions.
Abstract: The results of a photographic technique for the determination of the complete temperature distribution in the orthogonal metal cutting process are presented; they are found to disagree with previous theoretical predictions. The temperatures along the tool rake face are of particular interest because they are thought to affect the wear of the cutting tool and friction between the chip and tool; it is found that these temperatures have been considerably over-estimated by previous work. By introducing the width of the secondary deformation zone, i.e. the extent of sub-surface deformation due to friction at the tool-chip interface, as a new variable, it is found that more consistent predictions of rake face temperatures can be made. From this work information has been obtained on the shape of the zones of plastic deformation in metal cutting and on the distribution of heat generation within these zones.
Citations
More filters
Book
13 Apr 2000
TL;DR: In this paper, the authors discuss the application of metal cutting to manufacturing problems, including the design of real-time trajectory generation and interpolation algorithms, and CNC-oriented error analysis.
Abstract: Metal cutting is a widely used method of producing manufactured products. The technology of metal cutting has advanced considerably along with new materials, computers, and sensors. This new edition treats the scientific principles of metal cutting and their practical application to manufacturing problems. It begins with metal cutting mechanics, principles of vibration, and experimental modal analysis applied to solving shop floor problems. Notable is the in-depth coverage of chatter vibrations, a problem experienced daily by manufacturing engineers. The essential topics of programming, design, and automation of CNC (computer numerical control) machine tools, NC (numerical control) programming, and CAD/CAM technology are discussed. The text also covers the selection of drive actuators, feedback sensors, modeling and control of feed drives, the design of real time trajectory generation and interpolation algorithms, and CNC-oriented error analysis in detail. Each chapter includes examples drawn from industry, design projects, and homework problems. This book is ideal for advanced undergraduate and graduate students, as well as practicing engineers.

1,854 citations

Journal ArticleDOI
TL;DR: In this article, the authors present a review of previous research on heat generation and heat dissipation in the orthogonal machining process and propose some modelling requirements for computer simulation of high speed machining processes.
Abstract: Determination of the maximum temperature and temperature distribution along the rake face of the cutting tool is of particular importance because of its controlling influence on tool life, as well as, the quality of the machined part. Numerous attempts have been made to approach the problem with different methods including experimental, analytical and numerical analysis. Although considerable research effort has been made on the thermal problem in metal cutting, there is hardly a consensus on the basics principles. The unique tribological contact phenomenon, which occur in metal cutting is highly localized and non-linear, and occurs at high temperatures, high pressures and high strains. This has made it extremely difficult to predict in a precise manner or even assess the performance of various models developed for modelling the machining process. Accurate and repeatable heat and temperature prediction remains challenging due to the complexity of the contact phenomena in the cutting process. In this paper, previous research on heat generation and heat dissipation in the orthogonal machining process is critically reviewed. In addition, temperature measurement techniques applied in metal cutting are briefly reviewed. The emphasis is on the comparability of test results, as well as, the relevance of temperature measurement method to high speed cutting. New temperature measurement results obtained by a thermal imaging camera in high speed cutting of high strength alloys are also presented. Finally, the latest work on estimation of heat generation, heat partition and temperature distribution in metal machining is reviewed. This includes an exploration of the different simplifying assumptions related to the geometry of the process components, material properties, boundary conditions and heat partition. The paper then proposes some modelling requirements for computer simulation of high speed machining processes.

541 citations


Cites methods from "Temperatures in Orthogonal Metal Cu..."

  • ...Boothroyd also applied the finite difference technique to measure and calculate the heat generation rates in the primary and secondary deformation zones based on the temperature variations in preheated workpieces using an IR photography technique [60]....

    [...]

Journal ArticleDOI
01 Dec 1984-Wear
TL;DR: In this paper, an analytical method is presented which enables the crater and flank wear of tungsten carbide tools to be predicted for a wide variety of tool shapes and cutting conditions in practical turning operations based on orthogonal cutting data from machining and two wear characteristic constants.

288 citations

Book ChapterDOI
01 Jan 2000
TL;DR: In this article, the role of heat in limiting the rate of metal removal when cutting the higher melting point metals is discussed. But, as pointed out, there is no direct relationship between cutting forces or power consumption and the temperature near the cutting edge, and the most important heat source responsible for raising the temperature of a tool is the flow-zone where the chip is seized to the rake face of the tool.
Abstract: Publisher Summary This chapter focuses on the role of heat in limiting the rate of metal removal when cutting the higher melting point metals. The power consumed in metal cutting is largely converted into heat near the cutting edge of the tool, and many of the economic and technical problems of machining are caused directly or indirectly by this heating action. The bulk of cutting, however, is carried out on steel and cast iron, and it is in the cutting of these, together with the nickel-based alloys, that the most serious technical and economic problems occur. With these higher melting point metals and alloys, the tools are heated to high temperatures as metal removal rate increases and, above certain critical speeds, the tools tend to collapse after a very short cutting time under the influence of stress and temperature. It is, therefore, important to understand the factors, which influence the generation of heat. The most important heat source responsible for raising the temperature of the tool is the flow-zone where the chip is seized to the rake face of the tool. The amount of heat required to raise the temperature of the very thin flow-zone is a small fraction of the total energy expended in cutting, and the volume of metal heated in the flow-zone may vary considerably. Therefore, there is no direct relationship between cutting forces or power consumption and the temperature near the cutting edge.

259 citations

Journal ArticleDOI
TL;DR: In this paper, a new approach is taken in that the analysis is made in two separate parts, namely, the work material side and the chip side of the shear plane and then combined.

254 citations

References
More filters
Journal ArticleDOI
01 Jun 1959
TL;DR: In this paper, an experimental technique was developed for observing the cutting process during slow orthogonal cutting of mild steel, and the theory was extended by including the effect of work-hardening and it appeared that consistency had been regained.
Abstract: In an attempt to overcome the deficiencies of existing theories of cutting, an experimental technique was developed for observing the cutting process during slow orthogonal cutting of mild steel. An attempt to find consistency between the observations and the ideal theory of plasticity failed. Consequently the theory was extended by including the effect of work- hardening and, in spite of the laborious nature of the analysis, it appeared that consistency had been regained. This led to a novel and physically consistent picture of the cutting process, which was taking place during the tests.

178 citations

Journal ArticleDOI
TL;DR: In this paper, an experimental technique has been developed for the measurement of the temperature distribution in the deformation zone and in the chip and tool during orthogonal cutting, where the cutting edge of the tool is perpendicular to the direction of relative motion of the workpiece and tool.
Abstract: An experimental technique has been developed for the measurement of the temperature distribution in the deformation zone and in the chip and tool during orthogonal cutting. The term orthogonal cutting is used for the special case where the cutting edge of the tool is perpendicular to the direction of relative motion of the workpiece and tool. The method involves photographing the chip, tool and workpiece in a plane perpendicular to the cutting edge, using an infra-red sensitive photographic plate. The optical density of the plate is determined over the relevant field by means of a microdensitometer. A heated tapered strip, on which the temperature distribution is measured by means of a series of thermocouples, is photographed simultaneously with the tool and workpiece. This enables the optical density of the plate to be calibrated in terms of temperature, and the temperature distribution over the chip, tool and workpiece can hence be determined. The effect of surface emissivity and of other factors on the accuracy of the technique are considered, and the results of an experiment using the photographic technique are presented and discussed in relation to previous theoretical and experimental work.

83 citations

Journal ArticleDOI
TL;DR: In this article, relaxation and analytical methods of solution have been developed and applied to the work material, the chip and the tool considered as three separate problems and compared with other analytical solutions and with indirect experimental evidence of the temperatures attained.
Abstract: The problem investigated involves consideration of the temperature distribution in a body moving relative to sources of heat. Relaxation and analytical methods of solution have been developed and applied to the work material, the chip and the tool considered as three separate problems. The results obtained have been compared with other analytical solutions and with indirect experimental evidence of the temperatures attained. The application of the methods has been restricted to the simplest ideal model of the cutting process. The methods may be modified to incorporate the effect of temperature on the thermal properties, yield stress, etc., of the work material and are capable of a wider application to analogous heat flow problems.

65 citations

Journal ArticleDOI
TL;DR: In this article, it is shown that the effective shear angle will be smaller at slow speeds, for given values of tool rake angle and tool-chip interface friction, than at high speed sowing to the increase in width of the deforming zone with decrease in cutting speed.

33 citations

Journal ArticleDOI
01 Jun 1961
TL;DR: In order to determine the influence of the rate of strain-hardening (that is, rate of increase of flow stress with straining) on the machining process, cutting tests were carried out on a material as mentioned in this paper.
Abstract: In order to determine the influence of the rate of strain-hardening (that is, rate of increase of flow stress with straining) on the machining process, cutting tests were carried out on a material ...

22 citations