Mechanics of high speed cutting with curvilinear edge tools

Yiǧit Karpat, Tuǧrul Özel

Research output: Contribution to journalArticlepeer-review

88 Scopus citations

Abstract

High speed cutting is advantageous due to the reduced forces and power, increased energy savings, and overall improved productivity for discrete-part metal manufacturing. However, tool edge geometry and combined cutting conditions highly affects the performance of high speed cutting. In this study, mechanics of cutting with curvilinear (round and oval-like) edge preparation tools in the presence of dead metal zone has been presented to investigate the effects of edge geometry and cutting conditions on the friction and resultant tool temperatures. An analytical slip-line field model is utilized to study the cutting mechanics and friction at the tool-chip and tool-workpiece interfaces in the presence of the dead metal zone in machining with negative rake curvilinear PCBN tools. Inserts with six different edge designs, including a chamfered edge, are tested with a set of orthogonal cutting experiments on AISI 4340 steel. Friction conditions in each different edge design are identified by utilizing the forces and chip geometries measured. Finite-element simulations are conducted using the friction conditions identified and process predictions are compared with experiments. Analyses of temperature, strain, and stress fields are utilized in understanding the mechanics of machining with curvilinear tools.

Original languageEnglish (US)
Pages (from-to)195-208
Number of pages14
JournalInternational Journal of Machine Tools and Manufacture
Volume48
Issue number2
DOIs
StatePublished - Feb 2008

All Science Journal Classification (ASJC) codes

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

Keywords

  • Cutting
  • Dead metal zone
  • Friction factor
  • Round edge tools
  • Slip line field analysis

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