Model of Shear Slipping Deformation and its Cutting Energy Consumed for High Speed Machining

Abstract:

The characteristics of serrated chips were analyzed using the theory of shear-slipping deformation at high speed cutting, with geometric and mathematic models of the chip built. Deformation of continuous chip for scissile metal materials can be analyzed and controlled by analogous methods that are employed at normal cutting speed. Geometrical model about serrated chip for difficult-to-cut material under orthogonal cutting condition is offered by proper simplifying. The nonlinear equations of indices related to some factors for measuring deformation degree of chip have been ascertained. Based on the condition fo forces equilibrium with respect to single serrated chip at the moment when it is to be in shear instability, forces equilibrium equations are obtained, with shear force and shear velocity as well as friction force and flowing velocity for a chip segment found. Finally, energy equations of cutting are acquired from deformation energy and friction work consumed in the course of chip formation, which can be offered to the further study of mechanism of high speed machining and the design of high speed machine tool.

• Periodical: Advanced Materials Research (Volumes 602-604)
• Pages: 1967-1970
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.602-604.1967
• Online since: December 2012
• Authors: Hu Ping An, Zhi Yuan Rui, Rui Feng Wang, Zhi Mei Zhang
• Keywords: Cutting Model, Energy Equation, High Speed Machining, Serrated Chip, Shear Slipping

References

[1] Schulz H, Abele E. The High Speed Machining Fundamentals and Applications[M]. Scientific Press. 2010.7, in chinese

[2] J. Sun, Y.B. Guo. A new multi-view approach to characterize 3D chip morphology and properties in end milling titanium Ti-6Al-4V[J]. International Journal of Machine Tools & Manufacture, 2008 (48): 1486-1494

DOI: 10.1016/j.ijmachtools.2008.04.002

[3] G. Sutter. Chip geometries during high-speed machining for orthogonal cutting conditions[J]. International Journal of Machine Tools & Manufacture, 2005 (45): 719-726

DOI: 10.1016/j.ijmachtools.2004.09.018

[4] Calamaz M, Coupard D, Girot F. A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti-6Al-4V[J]. International Journal of Machine Tools & Manufacture, 2008 (48 ): 275-288

DOI: 10.1016/j.ijmachtools.2007.10.014

[5] Zhang S, Guo Y.B.. An experimental and analytical analysis on chip morphology, phase transformation, oxidation, and their relationships in finish hard milling[J]. International Journal of Machine Tools & Manufacture, 2009 (48): 805-813

DOI: 10.1016/j.ijmachtools.2009.06.006

[6] Cotterell M, Byrne G. Characterisation of chip formation during orthogonal cutting of titanium alloy Ti-6Al-4V[J]. CIRP Journal of Manufacturing Science and Technology, 2008 (1): 81-85

DOI: 10.1016/j.cirpj.2008.09.017