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Chip formation

About: Chip formation is a research topic. Over the lifetime, 2864 publications have been published within this topic receiving 68576 citations.


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Book
15 Mar 1960
TL;DR: In this paper, the authors describe typical cutting operations, including: Elastic Behaviour Plastic Behaviour Fracture Dynamometry Shear Strain in Cutting Shear Stress in Cutting Friction Wear and Tool Life Cutting Temperatures Cutting Fields Tool Materials Work Material Considerations Complex Tools Surface Integrity Chip Control Optimisation Modeling of Chip Formation Precision Engineering Unusual Applications of the Metal Cutting Process
Abstract: Table of Contents Preface Symbols Introduction Typical Cutting Operations Mechanics of Steady State Elastic Behaviour Plastic Behaviour Fracture Dynamometry Shear Strain in Cutting Shear Stress in Cutting Friction Wear and Tool Life Cutting Temperatures Cutting Fields Tool Materials Work Material Considerations Complex Tools Surface Integrity Chip Control Optimisation Modeling of Chip Formation Precision Engineering Unusual Applications of the Metal Cutting Process

2,229 citations

Journal ArticleDOI
TL;DR: An analysis of the chip geometry and the force system found in the case of orthogonal cutting accompanied by a type 2 chip has yielded a collection of useful equations which make possible the study of actual machining operations in terms of basic mechanical quantities as mentioned in this paper.
Abstract: An analysis of the chip geometry and the force system found in the case of orthogonal cutting accompanied by a type 2 chip has yielded a collection of useful equations which make possible the study of actual machining operations in terms of basic mechanical quantities. The shearing strain undergone by the metal during chip formation, and the velocities of shear and of chip flow are among the geometrical quantities which can be quantitatively determined. The force relationships permit calculation of such quantities as the various significant force components, stresses, the coefficient of friction between chip and cutting tool, and the work done in shearing the metal and in overcoming friction on the tool face. The experimental methods by which such analyses can be readily made are described. Observed and calculated values from typical tests are presented.

1,152 citations

Book
23 Oct 1996
TL;DR: Turning Boring Drilling Reaming Milling Planing and Shaping Broaching Tapping and Threading Grinding and Related Abrasive Processes Roller Burnishing Deburring Examples Problems References MACHINE TOOLS Introduction Production Machine Tools CNC Machine Tools and Cellular Manufacturing Systems Machine Tool Structures Slides and Guideways Axis Drives Spindles Coolant Systems Tool Changing Systems.
Abstract: INTRODUCTION Scope of the Subject Historical Development Types of Production References METAL CUTTING OPERATIONS Introduction Turning Boring Drilling Reaming Milling Planing and Shaping Broaching Tapping and Threading Grinding and Related Abrasive Processes Roller Burnishing Deburring Examples Problems References MACHINE TOOLS Introduction Production Machine Tools CNC Machine Tools and Cellular Manufacturing Systems Machine Tool Structures Slides and Guideways Axis Drives Spindles Coolant Systems Tool Changing Systems Examples References CUTTING TOOLS Introduction Cutting Tool Materials Tool Coatings Basic Types of Cutting Tools Turning Tools Boring Tools Milling Tools Drilling Tools Reamers Threading Tools Grinding Wheels Microsizing and Honing Tools Burnishing Tools Examples Problems References TOOLHOLDERS AND WORKHOLDERS Introduction Toolholding Systems Toolholder/Spindle Connections Cutting Tool Clamping Systems Balancing Requirements for Toolholders Fixtures Examples Problems References MECHANICS OF CUTTING Introduction Measurement of Cutting Forces and Chip Thickness Force Components Empirical Force Models Specific Cutting Power Chip Formation and Primary Plastic Deformation Tool-Chip Friction and Secondary Deformation Shear Plane and Slip Line Theories for Continuous Chip Formation Shear Plane Models for Oblique Cutting Shear Zone Models Minimum Work and Uniqueness Assumptions Finite Element Models Discontinuous Chip Formation Built-up Edge Formation Examples Problems References CUTTING TEMPERATURES Introduction Measurement of Cutting Temperatures Factors Affecting Cutting Temperatures Analytical Models for Steady-State Temperatures Finite Element and Other Numerical Models Temperatures in Interrupted Cutting Temperatures in Drilling Thermal Expansion Examples Problems References MACHINING PROCESS ANALYSIS Introduction Turning Boring Milling Drilling Force Equations and Baseline Data Process Simulation Examples Finite Element Analysis for Clamping, Fixturing, and Workpiece Distortion Applications Finite Element Application Examples Examples Problems References TOOL WEAR AND TOOL LIFE Introduction Types of Tool Wear Measurement of Tool Wear Tool Wear Mechanisms Tool Wear--Material Considerations Tool Life Testing Tool Life Equations Prediction of Tool Wear Rates Tool Fracture and Edge Chipping Drill Wear and Breakage Thermal Cracking and Tool Fracture in Milling Tool Wear Monitoring Examples Problems References SURFACE FINISH AND INTEGRITY Introduction Measurement of Surface Finish Surface Finish in Turning and Boring Surface Finish in Milling Surface Finish in Drilling and Reaming Surface Finish in Grinding Residual Stresses in Machined Surfaces White Layer Formation Surface Burn in Grinding Examples Problems References MACHINABILITY OF MATERIALS Introduction Machinability Criteria, Tests, and Indices Chip Control Burr Formation and Control Machinability of Engineering Materials References MACHINING DYNAMICS Introduction Vibration Analysis Methods Vibration of Discrete (Lumped Mass) Systems Types of Machine Tool Vibration Forced Vibration Self-Excited Vibrations (Chatter) Chatter Prediction Vibration Control Active Vibration Control Examples References MACHINING ECONOMICS AND OPTIMIZATION Introduction Role of a Computerized Optimization System Economic Considerations Optimization of Manufacturing Systems--Basic Factors Optimization of Machining Conditions Formulation of the Optimization Problem Optimization Techniques Numerical Examples Problems References CUTTING FLUIDS Introduction Types of Cutting Fluids Coolant Application Filtering Condition Monitoring and Waste Treatment Health and Safety Concerns Dry and Near-Dry Machining Methods Test Procedure for Cutting Fluid Evaluation References HIGH THROUGHPUT AND AGILE MACHINING Introduction High Throughput Machining Agile Machining Systems Tooling and Fixturing Materials Handling Systems References DESIGN FOR MACHINING Introduction Machining Costs General Design for Machining Rules Special Considerations for Specific Types of Equipment and Operations CAPP and DFM Programs Examples References INDEX

660 citations

Journal ArticleDOI
TL;DR: In this article, a new material constitutive law is implemented in a 2D finite element model to analyse the chip formation and shear localisation when machining titanium alloys.
Abstract: A new material constitutive law is implemented in a 2D finite element model to analyse the chip formation and shear localisation when machining titanium alloys. The numerical simulations use a commercial finite element software (FORGE 2005®) able to solve complex thermo-mechanical problems. One of the main machining characteristics of titanium alloys is to produce segmented chips for a wide range of cutting speeds and feeds. The present study assumes that the chip segmentation is only induced by adiabatic shear banding, without material failure in the primary shear zone. The new developed model takes into account the influence of strain, strain rate and temperature on the flow stress and also introduces a strain softening effect. The tool chip friction is managed by a combined Coulomb–Tresca friction law. The influence of two different strain softening levels and machining parameters on the cutting forces and chip morphology has been studied. Chip morphology, cutting and feed forces predicted by numerical simulations are compared with experimental results.

533 citations

Journal ArticleDOI
01 Jan 1997-Wear
TL;DR: In this article, the authors investigated the thermal properties of high-speed machining of Inconel 718 and Ti 6Al 6V 2Sn alloys from a thermal point of view.

500 citations


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Performance
Metrics
No. of papers in the topic in previous years
YearPapers
202381
2022149
2021151
2020139
2019150
2018164