Beruflich Dokumente
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Abstract
A fundamental and quantitative analysis of the tool-chip friction helps to better understand the mechanism of chip formation and other
complex phenomena in machining with a large negative rake angle tool. Built upon Lee and Shaffers model, this paper presents an analytical
slip-line approach to investigate how the negative tool rake angle and the cutting speed affect the tool-chip friction, and how the tool-chip
friction further affects machining performances, such as the ratio of the cutting force to the thrust force, the chip thickness ratio, the geometry
of the shear zone, and the geometry of the stagnation zone of material flow adjacent to the tool rake face. Published experimental data covering
a wide range of negative tool rake angles and cutting speeds are employed to validate the analytical model. The predicted force ratio and chip
thickness ratio are in good agreement with the experimental data. Different effects resulting from the positive and negative rake angles on the
tool-chip friction are compared and analyzed.
2004 Elsevier B.V. All rights reserved.
Keywords: Friction; Machining; Large negative rake angle; Slip-line approach
1. Introduction
Tool-chip friction and work material properties have long
been recognized as two unsolved bottleneck problems in fundamental machining research. Previous studies on the toolchip friction have been primarily focused in machining with
a positive rake angle tool, with various theories and experimental techniques having been proposed [14]. The study
on the tool-chip friction in machining with a negative rake
angle tool, especially with those tools having the rake angle
greater than 40 , is still limited. This latter study receives
growing attention in recent years due to the need to better
understand the mechanism of chip formation in a variety of
both traditional and emerging machining techniques, such
as:
(1) grinding [5],
(2) machining with chamfered tools [6],
(3) hard turning [7],
0043-1648/$ see front matter 2004 Elsevier B.V. All rights reserved.
doi:10.1016/j.wear.2004.09.047
said advantages, various slip-line models have been developed in the past decades for different machining operations
[1115]. For example, in their classic paper, Lee and Shaffer
[11] developed two slip-line models for orthogonal metal cutting with continuous chip formation. Their first model does
not consider built-up edge (BUE) formation and is only applicable to machining with a large positive rake angle tool
and low tool-chip friction. Their second model accounts for
BUE formation and is applicable to machining with a small
positive or a small negative rake angle tool with severe (intensive) tool-chip friction. Compared to their first model that
has been broadly cited in numerous machining literatures,
the Lee and Shaffers second model receives less attention
in the international machining research community. Part of
the reason, as some researchers commented, is that the BUE
size predicted from their second model is fairly small and
often not observed under the cutting conditions commonly
employed in machining tests.
In a most recent investigation of machining with a large
negative rake angle tool, Ohbuchi and Obikawa [16] showed
some photomicroscopes of material flow in the shear zone
and confirmed the existence of a triangular stagnation zone
of material flow ahead of the tool rake face, which has been
previously reported by Komanduri [5] and Kita et al. [1719].
The stagnation zone is very similar to a BUE in appearance
except that the former has a more stable structure. Based on
the experimental observations of the geometry and dimension
of the stagnation zone, Ohbuchi and Obikawa [16] employed
the finite element method to model chip formation in machining with a large negative rake angle tool. With its rake angle
assumed to be 0 or +10 , the stagnation zone was attached
to the cutting tool as a single solid body to perform finite
element analysis.
In the present study, the Lee and Shaffers second model
[11] stated before is extended to model chip formation in
machining with a large negative rake angle tool. The goal is
to develop an analytical slip-line approach to investigate the
tool-chip friction under such special machining conditions.
Two major objectives of this study include understanding
how the tool rake angle and the cutting speed affect the
tool-chip friction, and how the tool-chip friction further
affects machining performances, the geometry of the shear
zone, and the geometry of the stagnation zone. Tool-chip
friction serves in this paper as an important bridge to link
the tool geometry and cutting conditions with machining
performances. The similarities and differences between
machining processes with both negative and positive rake
angle tools are compared. Published experimental data [20]
in the machining of a leadantimony alloy are employed to
validate the analytical model. Although this type of alloy
is not extensively employed nowadays, the data [20] are
still valuable because they are very comprehensive covering
a wide range of negative tool rake angles and cutting
speeds.
It needs to be pointed out that the scope of the present
study is limited to orthogonal metal cutting with sharp edge
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Fig. 1. Machining with a large negative rake angle tool: (a) extended Lee
and Shaffers model [11] and (b) hodograph.
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cos1
2
k
(1)
(2)
(PA /k) 1
2
(3)
+ 1
4
(4)
(5)
The length l (i.e., CE) and the height h (i.e., EF) of the
stagnation zone are determined by
l
sin((/4) + ) sin( + 1 )
=
t1
cos cos 1
(6)
h
l
sin((/2) + )
=
t1
t1 cos ((/2) + + 1 )
(7)
(8)
(9)
1
ef
cos1
2
k
(10)
(11)
(12)
The first terms on the right-hand side of Eqs. (11) and (12)
are two force components transmitted through the slip-line
AF. Note that Eqs. (11) and (12) contain the material shear
flow stress k, which is an unknown variable. Therefore, the
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sin((/4) + ) sin( + 1 )
cos cos 1
(13)
Ft
= (1 + 2) tan 1 + [1 + 2 + 2 + 2ef
kt1 w
+ sin(2ef )]
sin((/4) + ) sin( + 1 )
cos cos 1
(14)
is suggested:
2
Fc
Fc
Ft expe
Ft pred
D =
2
+ tt21
tt21
pred
(15)
expe
where D stands for the overall prediction error for the force
ratio Fc /Ft and the chip thickness ratio t2 /t1 , and the subscripts
pred and expe represent the predicted and experimental
values, respectively. The combination of /k and PA /k that
makes D minimum is chosen as the best-fitted combination
for the specific cutting operation investigated.
Fig. 3 shows how the method stated above is employed.
The input and output variables of the developed analytical
model are also shown in Fig. 3.
3. Experimental validation
Findley and Reed [20] have performed extensive orthogonal cutting tests covering a very broad range of cutting speeds
and negative tool rake angles up to 60 . The tool material
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Fig. 5. Predicted and experimental force ratio and chip thickness ratio at the
tool rake angle of 40 for varying cutting speeds.
Fig. 4. Predicted and experimental force ratio and chip thickness ratio at the
cutting speeds of (a) Vc = 120 m/min and (b) Vc = 170 m/min for varying tool
rake angles.
employed was primarily tungsten carbide. The work material employed was a casting of leadantimony alloy with the
following chemical composition: copper, none; tin, 0.06%;
lead, 88.85%; antimony, 10.9%; arsenic, 0.13%. Their experimental data of the cutting forces and the chip thickness, which were carefully measured in the cutting tests,
are employed in the present study to validate the analytical
model.
Note that Findley and Reed [20] also reported that discontinuous and segmented chips were generated for some
particular combinations of the negative tool rake angle
and the cutting speed. Only those combinations that generate continuous chip formation are selected for experimentally validating the analytical model presented in this
paper.
3.1. Varying tool rake angles
Fig. 4 shows the comparison of the predicted and experimental force ratio Fc /Ft and chip thickness ratio t2 /t1 for
the tool rake angles ranging from 0 to 60 . The predicted
results are generated using the method described in Section
2.3, with the best-fitted combination of /k and PA /k for each
cutting operation given later in Section 4.
As seen in Fig. 4, both the predicted Fc /Ft and t2 /t1 are
in good agreement with the experimental results for the tool
rake angles 1 from 20 to 60 . A relatively large error
of prediction exists for 1 of 0 , possibly due to the predicted
size of the stagnation zone being larger than its actual size
at this specific rake angle. Comparing the prediction error
for 1 from 60 to 20 and the prediction error for 1
from 20 to 0 , it can be said that the developed analytical
model does work, as expected for large negative rake angles.
For small negative rake angles, the models developed by other
researchers, i.e., by Kopalinsky and Oxley [26], may generate
more accurate predictions.
A more detailed analysis of the results shown in Fig. 4
demonstrates that a negative rake angle and a positive rake
angle can affect machining processes quite differently. For
example:
(1) When using a negative 1 , the force ratio Fc /Ft is
typically less than 1.0, which means the cutting force
Fc is less than the thrust force Ft . Other researchers
[5,16,19,26] also have confirmed this unique phenomenon. However, as well known, Fc is generally larger
than Ft in machining with a positive 1 .
(2) The force ratio Fc /Ft decreases with increase in the absolute value of negative 1 . A decrease in positive 1
decreases Fc /Ft .
(3) The chip thickness ratio t2 /t1 decreases with decrease in
the absolute value of negative 1 . An increase in positive
1 decreases t2 /t1 .
3.2. Varying cutting speeds
Fig. 5 shows the comparison of the predicted and experimental force ratio Fc /Ft and chip thickness ratio t2 /t1
at the cutting speeds ranging from 120 to 1120 m/min.
The tool rake angle 1 kept constant at 40 . As seen
from Fig. 5, good agreement between the predicted and experimental Fc /Ft and t2 /t1 is also achieved. The predicted
chip thickness ratio t2 /t1 agrees very well with the experimental results, with the average error of predictions less
than 1%.
Fig. 5 also shows that as the cutting speed increases, the
force ratio Fc /Ft increases, while the chip thickness ratio t2 /t1
decreases. The effect of the cutting speed appears similar for
both negative and positive tool rake angles.
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Fig. 8. Effect of tool-chip friction factor /k on the force and chip thickness
ratios.
Fig. 6. Tool-chip friction factor /k and hydrostatic pressure PA /k for the
same cutting conditions given in Fig. 4.
Fig. 9. Effects of tool-chip friction factor /k on (a) major angles and (b) the
coefficient of friction.
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6. Conclusions
Fig. 10. Effect of tool-chip friction factor /k on the length and height of the
stagnation zone.
References
Fig. 11. Predicted stagnation-zone geometry for the tool rake angle of 40
at different cutting speeds (to scale).
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