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.
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e-mail: roy.schimmel@gm.com
e-mail: endres@umich.edu
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August 2002
Technical Papers
Application of an Internally Consistent Material Model to Determine the Effect of Tool Edge Geometry in Orthogonal Machining
Roy J. Schimmel,
e-mail: roy.schimmel@gm.com
Roy J. Schimmel
Dept. of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125
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William J. Endres,
e-mail: endres@umich.edu
William J. Endres
Dept. of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125
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Robin Stevenson
Robin Stevenson
Enterprise Systems Laboratory, General Motors R & D Center, Warren, MI 48090-9055
Search for other works by this author on:
Roy J. Schimmel
Dept. of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125
e-mail: roy.schimmel@gm.com
William J. Endres
Dept. of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125
e-mail: endres@umich.edu
Robin Stevenson
Enterprise Systems Laboratory, General Motors R & D Center, Warren, MI 48090-9055
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received February 1999; revised May 2001. Associate Editor: M. Elbestawi.
J. Manuf. Sci. Eng. Aug 2002, 124(3): 536-543 (8 pages)
Published Online: July 11, 2002
Article history
Received:
February 1, 1999
Revised:
May 1, 2001
Online:
July 11, 2002
Citation
Schimmel, R. J., Endres, W. J., and Stevenson, R. (July 11, 2002). "Application of an Internally Consistent Material Model to Determine the Effect of Tool Edge Geometry in Orthogonal Machining ." ASME. J. Manuf. Sci. Eng. August 2002; 124(3): 536–543. https://doi.org/10.1115/1.1448334
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