On the inadequacy of the single-shear plane model of chip formation

International Journal of Mechanical Sciences

Volumn 47, Issue 11, 2005, Pages 1649-1672

  Astakhov, Viktor P ^a  

^a Astakhov Tool Service   (United States)

Author keywords

Chip formation; Metal cutting; Predicted and experimental results; Single shear plane model; Theory

Indexed keywords

BRITTLENESS; COMPUTER SIMULATION; MATHEMATICAL MODELS; METAL CUTTING; STRAIN;

FORCE DIAGRAMS; METAL CUTTING THEORY; SHEAR STRAIN; SINGLE-SHEAR PLANE MODEL;

DYNAMIC MECHANICAL ANALYSIS;

EID: 24944486873     PISSN: 00207403     EISSN: None     Source Type: Journal    
DOI: 10.1016/j.ijmecsci.2005.07.002     Document Type: Article

References (88)

1. Usui E, Shirakashi T. Mechanics of metal cutting - from "description" to "predictive" theory. In: On the art of cutting metals - 75 years later. Phoenix, USA: Production Engineering Division (PED), ASME; 1982.
2. E. Usui Progress of "predictive" theories in metal cutting JSME International Journal 31 1988 363 369
3. Armarego EJA. Predictive modeling of machining operations - a means of bridging the gap between the theory and practice - a keynote paper. In: The 13th symposium on engineering applications of mechanics. Hamilton, ON, Canada: CMSE; 1996.
4. W.J. Endres, R.E. Devor, and S.G. Kapoor A dual-mechanism approach to the prediction of machining forces, part 1: model development ASME Journal of Engineering for Industry 117 1995 526 533
5. J. Kopac, and S. Dolinsek Advantages of experimental research over theoretical models in the field of metal cutting Experimental Techniques 20 1996 24 28
6. E.J. Armarego, and R.H. Brown The machining of metals 1969 Prentice-Hall New Jersey, USA
7. M.C. Shaw Metal cutting principles 2nd ed. 2005 Oxford University Press Oxford
8. AdvantEdge(tm) Modelingsoftware. Thirdwavesystems, (http://www. thirdwavesys.com ), 2004.
9. E.P. DeGarmo, J.T. Black, and R.A. Kohser Materials and processes in manufacturing 9th ed. 2003 Wiley New York
10. S. Kalpakjian, and S.R. Schmid Manufacturing engineering and technology 2001 Prentice-Hall New Jersey
11. F.Y. Gorczyca Application of metal cutting theory 1987 Industrial Press New York
12. M.C. Shaw Metal cutting principles 1984 Oxford Science Publications Oxford
13. Jawahir IS, Balaji AK, Stevenson R, van Luttervelt CA. Towards predictive modeling and optimization of machining operations. In: Manufacturing science and engineering. Proceedings of the 1997 ASME international mechanical engineering congress and exposition. Dallas, TX: ASME; 1997.
14. Jawahir IS, Zhang JP. An analysis of chip curl development, chip deformation and chip breaking in orthogonal machining. Transactions of NAMRI/SME, vol. XXIII; 1995. p. 109-14.
15. N. Fang, I.S. Jawahir, and P.L.B. Oxley A universal slip-line field model with non-unique solutions for machining with curled chip formation and a restricted contact tool International Journal of Mechanical Sciences 43 2001 557 580
16. N. Fang, and I.S. Jawahir Analytical predictions and experimental validation of cutting force ratio, chip thickness, and chip back-flow angle in restricted contact machining using the universal slip-line model International Journal of Machine Tools and Manufacturing 42 2002 681 694
17. N. Fang, I.S. Jawahir, and P.L.B. Oxley A universal slip-line model with non-unique solutions for machining with curled chip formation and a restricted contact tool International Journal of Mechanical Sciences 43 2001 557 580
18. I. Finnie Review of the metal-cutting analysis of the past hundred years Mechanical Engineering 78 1956 715 721
19. V. Piispanen Lastunmuodostumisen teoriaa Teknillinen Aikakauslehti 27 1937 315 322
20. V. Piispanen Theory of formation of metal chips Journal of Applied Physics 19 1948 876 881
21. P.L.B. Oxley Mechanics of machining: an analytical approach to assessing machinability 1989 Wiley New York, USA
22. I. Time Resistance of metals and wood to cutting 1870 Dermacow Press House St. Petersbourg, Russia [in Russian]
23. H. Tresca Mémores sur le Rabotage des Metaux Bulletin de la Société d'Encouragement pour l'Industrie Nationale 15 1873 585 685
24. I. Time Memore sur le Rabotage de Métaux 1877 St. Petersbourg Russia
25. V.P. Astakhov Metal cutting mechanics 1998 CRC Press Boca Raton, USA
26. Zvorykin KA. On the force and energy needed to separate the chip from the workpiece. 1896;123:57-96 [in Russian].
27. O.W. Boston A bibliography on cutting of metals 1945 ASME New York
28. Briks AA. Metal cutting. Publ. House; 1896 [in Russian].
29. Zorev NN, editor. Metal cutting mechanics. Oxford: Pergamon Press; 1966.
30. W. Johnson, and P.B. Mellor Engineering plasticity 1973 Van Nostrand Reinhold Company London, Inglaterra
31. W.B. Palmer, and P.L.B. Oxley Mechanics of metal cutting Proceedings of the Institution of Mechanical Engineers 173 1959 557 580
32. H. Kudo Some new slip-line solutions for two-dimensional steady-state machining International Journal of Mechanical Sciences 7 1965 43 55
33. K. Okushima, and K. Hitomi An analysis of the mechanism of orthogonal cutting and its application to discontinuous chip formation ASME Journal of Engineering for Industry 83 1961 545 556
34. H. Ernst, and M.E. Merchant Chip formation, friction and high quality machined surfaces. Surface treatment of metals ASM 29 1941 299 378
35. M.E. Merchant Mechanics of the metal cutting process. I. Orthogonal cutting and a type 2 chip Journal of Applied Physics 16 1945 267 275
36. E.H. Lee, and B.W. Shaffer The theory of plasticity applied to a problem of machining Journal of Applied Mechanics 18 1951 405 413
37. F. Reuleaux Über den taylor whiteschen werkzeugstahl verein sur berforderung des gewerbefleissen in preussen Sitzungsberichete 79 1900 179 220
38. A.G. Atkins Modelling metal cutting using modern ductile fracture mechanics: qualitative explanations for some longstanding problems International Journal of Mechanical Sciences 45 2003 373 396
39. E.P. DeGamo, J.T. Black, and R.A. Kohser Materials and processing in manufacturing 1988 Macmillan New York
40. V.P. Astakhov, M.O.M. Osman, and M.T. Hayajneh Re-evaluation of the basic mechanics of orthogonal cutting: velocity diagram, virtual work equation and upper-bound theorem International Journal of Machine Tools & Manufacturing 41 2001 393 418
41. J.T. Black, and J.M. Huang Shear strain model in metal cutting Manufacturing Science and Engineering MED-Vol.2-1 1995 283 302
42. E.P. DeGarmo, J.T. Black, and R.A. Kohser Materials and processes in manufacturing 1997 Prentice-Hall Upper Saddle River, NJ
43. Y. Altintas Manufacturing automation. Metal cutting mechanics, machine tool vibrations, and CNC design 2000 Cambridge University Press Cambridge
44. D.A. Stenphenson, and J.S. Agapiou Metal cutting theory and practice 1996 Marcel Dekker New York
45. A. Vyas, and M.C. Shaw Mechanism of saw-tooth chip formation in metal cutting ASME Journal of Manufacturing Science and Engineering 121 1999 163 172
46. J.E. Field, S.M. Walley, W.G. Proud, H.T. Goldrein, and C.R. Siviour Review of experimental techniques for high rate deformation and shock studies International Journal of Impact Engineering 30 2004 725 775
47. Rohr I, Nahme H, Thoma K. Material characterization and constitutive modelling of ductile high strength steel for a wide range of strain rates. International Journal of Impact Engineering 2005;31(4):401-33.
48. Tönshoff HK, Amor RB, Andrae P. Chip formation in high speed cutting (HSC), SME paper MR99-253. Dearborn MI: SME; 1999.
49. V.P. Astakhov, and S. Shvets The assessment of plastic deformation in metal cutting Journal of Materials Processing Technology 146 2004 193 202
50. Payton LN, Black JT. Low speed orthogonal machining of copper with hardness gradient. SME Technical Paper MR01-266; 2001. p. 1-8.
51. G. Dieter Mechanical metallurgy 1976 McGraw-Hill New York
52. Zorev NN. Results of work in the field of the mechanics of the metal cutting process. Proceedings of the IME conference on technical engineering manufacture, London; 1958.
53. V.P. Astakhov, and J.C. Outeiro Modeling of the contact stress distribution at the tool-chip interface Machining Science and Technology 9 2005 85 99
54. M.F. Poletica Contact loads on tool interfaces 1969 Mashinostroenie Moscow [in Russian]
55. T.N. Loladze Strength and wear of cutting tools 1958 Mashgiz Moscow [in Russian]
56. M. Kronenberg Machining science and application. Theory and practice for operation and development of machining processes 1966 Pergamon Press Oxford
57. I. Finnie, and M.C. Shaw The friction process in metal cutting Transactions of ASME 77 1956 1649 1657
58. E. Usui, and H. Takeyma A photoelastic analysis of machining stresses ASME Journal of Engineering for Industry 81 1960 303 308
59. J.S. Strenkowski, and K.-J. Moon Finite element prediction of chip geometry and tool/workpiece temperature distributions in orthogonal metal cutting ASME Journal of Engineering for Industry 112 1990 313 318
60. K. Komvopoulos, and S.A. Erpenbeck Finite element modeling of orthogonal metal cutting ASME Journal of Engineering for Industry 113 1991 253 267
61. Z.C. Lin, W.C. Pan, and S.P. Lo A study of orthogonal cutting with tool flank wear and sticking behaviour on the chip-tool interface Journal of Materials Processing Technology 52 1995 524 538
62. Z.C. Lin, and S.Y. Lin A coupled finite element model of thermo-elastic-plastic large deformation for orthogonal cutting Journal of Engineering Materials and Technology 114 1992 218 226
63. J.S. Strenkowski, and J.T. Carroll A finite element model of orthogonal metal cutting ASME Journal of Engineering for Industry 107 1985 349 354
64. W.J. Endres, R.E. Devor, and S.G. Kapoor A dual-mechanism approach to the prediction of machining forces. Part 2: calibration and validation ASME Journal of Engineering for Industry 117 1995 534 541
65. L. Olovsson, L. Nilsson, and K. Simonsson An ALE formulation for the solution of two-dimensional metal cutting problems Computers and Structures 72 1998 497 507
66. M. Kronenberg Machining science and application. Theory and practice for operation and development of machining processes 1966 Pergamon Press Oxford
67. Astakhov VP. Tribology of metal cutting. In: Totten HL, GE, editor. Mechanical tribology. New York: Marcel Dekker; 2004. p. 307-46.
68. R. Hill The mechanics of machining: a new approach Journal of the Mechanics and Physics of Solids 3 1954 47 53
69. C. Rubenstein A note concerning the inadmissibility of applying of minimum work principle to metal cutting ASME Journal of Engineering for Industry 105 1983 294 296
70. W. Dewhurst On the non-uniqueness of the machining process Proceedings of the Royal Society of London A 360 1978 587 609
71. H. Ernst Physics of metal cutting 1938 The Cincinnati Milling Machine Co. Cincinnati, OH, USA
72. E.M. Trent, and P.K. Wright Metal cutting 2000 Butterworth-Heinemann Boston
73. V.P. Astakhov A treatise on material characterization in the metal cutting process. Part 2: cutting as the fracture of workpiece material Journal of Materials Processing Technology 96 1999 34 41
74. Outeiro JC. Application of recent metal cutting approaches to the study of the machining residual stresses. Coimbra: Department of Mechanical Engineering, University of Coimbra; 2003. p. 340.
75. V.P. Astakhov Chapter 9: Tribology of metal cutting G.T.A.H. Liang Mechanical tribology, material characterization and application 2004 Marcel Dekker New York 307 346
76. Pugh HLD. Mechanics of metal cutting process. In: Proceedings of the IME conference on technical engineering manufacture, London; 1958.
77. Chisholm AWJ. A review of some basic research on the machining of metals. In: Proceedings of the IME conference on technical engineering manufacture, London; 1958.
78. J.A. Bailey, and G. Boothroyd Critical review of some previous work on the mechanics of the metal-cutting process ASME Journal of Engineering for Industry 90 1969 54 62
79. J.H. Creveling, T.F. Jordon, and E.G. Thomsen Some studies on angle relationship in metal cutting ASME Journal of Applied Mechanics 79 1958 127 138
80. R. Hill The mathematical theory of plasticity 1950 Oxford University Press London
81. A.G. Atkins, and Y.W. Mai Elastic and plastic fracture: metals, polymers. Ceramics, composites, biological materials 1985 Wiley New York
82. G. Boothroyd, and W.A. Knight Fundamentals of machining and machine tools 2nd ed. 1989 Marcel Dekker New York
83. T.H.C. Childs, K. Maekawa, T. Obikawa, and Y. Yamane Metal machining. Theory and application 2000 Arnold London
84. Ivester RW, Kennedy M, Davies M, Stevenson RJ, Thiele J, Furness R, Athavale S. Assessment of machining models: progress report. In: Proceedings of the third CIRP international workshop on modelling of machining operations. Sydney, Australia: University of New South Wales; 2000.
85. V.P. Astakhov The assessment of cutting tool wear International Journal of Machine Tools and Manufacture 44 2004 637 647
86. E. Eleftherion, and C.E. Bates Effect of inoculation on machinability of gray cast iron ASF Transactions 122 1999 659 669
87. Garry JRC, Wright IP. The cutting strength of cryogenic water. England: Ice Planetary Science Research Institute, Open University; 2000.
88. Astakhov VP, Outeiro JC. Modeling of the contact stress distribution at the tool-chip interface. In: Proceeding of the seventh CIRP international workshop on modeling of machining operations. Cluny, France: ENSAM; 2004.