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1 Introduction Merchant 关4兴, using energy minimization, found that this angle
could be determined if the average friction angle at the tool-chip
The physics of metal cutting involves complex interactions
interface were known. Various other researchers have developed
among a multitude of phenomena such as plasticity, friction, heat
2D models of machining by the use of slip line field theory 关5–7兴
generation, heat flow, material damage and phase changes that are used in conjunction with Hill’s theory of permissible intensity of
dealt with in separate disciplines such as mechanics, heat transfer, stress singularities as applicable to machining 关8兴. The most sig-
tribology, materials science and mathematics. Since the time of nificant contribution towards modeling of practical machining has
Tresca’s studies on the planing of metals, there have been signifi- been the parallel-sided shear zone theory of Oxley and co-workers
cant improvements in our understanding of machining resulting 关9–12兴. The unique feature of Oxley’s machining theory 关12兴 is
from advances in these disciplines. However, machining still that the dependence of material flow stress upon strain, strain rate
poses ample challenges to researchers. and temperature is considered to obtain the shear angle and
Machining process development involves determination of in- other outputs of interest. This theory has been modified to analyze
puts such as machine tool operating parameters and the cutting a range of machining operations 关13–15兴 and extensive experi-
tool geometry, material and coating to be adopted in order to mental validation of the theory has been carried out 关16兴. One
obtain desired values of outputs such as cutting force, chip mor- significant limitation of the model is the fact that it has been
phology, machined surface characteristics and tool life. Design almost exclusively applied to carbon steels. There is a need to
and development of machining processes and cutting tools is still extend the applicability of this theory to other materials com-
primarily based on empirical knowledge, with additional experi- monly machined.
mentation carried out as needed. This approach is costly, time
consuming and often leads to non-optimal manufacturing 关1兴.
Continuous enhancements to the accuracy of machining models 2 Description of Oxley’s Machining Theory
and determination of accurate values for critical inputs needed for
these models are prerequisites for scientific design of machining Oxley’s model of machining was developed based on experi-
processes. mental observations 关17兴 of the material deformation. As shown in
Over the past century and a half, many researchers have tried to Fig. 1, the deformation in metal cutting is concentrated in two
understand the machining process under the framework of plastic- zones—a primary shear zone centered about AB 共the nominal
ity theory. Piispanen 关2兴 and Ernst 关3兴 proposed the card model of shear ‘‘plane’’ of length L兲 and a secondary shear zone along the
chip formation in which the shear plane angle is unknown. tool-chip interface. Though the actual shapes of the two zones are
approximately as depicted in Fig. 1, the primary shear zone is
Contributed by the Manufacturing Engineering Division for publication in the
assumed to be parallel-sided and the secondary shear zone is as-
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received sumed to be of constant thickness, to simplify analysis. The pa-
March 2002; Revised June 2003. Associate Editor: Y. Shin. rameter c is used to represent the relative length of the primary
656 Õ Vol. 125, NOVEMBER 2003 Copyright © 2003 by ASME Transactions of the ASME
minimizes the overall cutting force 关19兴. This is taken to be the
correct value of ␦ and the corresponding shear plane angle, forces,
strain rates and temperatures are taken to be the actual values of
these output variables.
Oxley 关12兴 and co-workers developed a computer program to
carry out the above analysis. It is found that the analysis yields
results in good agreement with experiments when parameters
and are used to tune the model. Typical values of these param-
eters used by Oxley and co-workers range from 0.5 to 1.0 for
carbon steels.
冉 冉 冊冊冉 冉 冊冊
the shear stress int on the rake face are obtained from the corre-
sponding forces and the contact length. The normal stress on the ˙ T⫺T r m
⫽ 共 A⫹B n 兲 1⫹C ln 1⫺ (2)
rake face can be obtained in a different manner by assuming that ˙ 0 T m ⫺T r
the alpha slip line in the primary shear zone turns to meet the tool In the above equation, is the true stress, is the true strain, ˙ is
perpendicular to the rake face. The parameter c is fixed at the the strain rate, ˙ 0 is the reference strain rate, T is the temperature
value that causes n calculated by both ways to be the same 关11兴. of the material, T r is the reference temperature and T m is the
Assuming that there is sticking friction at the tool-chip inter- melting temperature. Brief descriptions of the MTS material
face, the shear strength of the chip (k chip ) at the average tempera- model and the power law material model used by Maekawa and
ture of the tool-chip interface should be equal to int . The maxi- co-workers are given in the Appendix. It is apparent that Oxley’s
mum temperature at the tool-chip interface is calculated using model can be extended to handle other materials by incorporating
equations derived from Boothroyd’s 关18兴 results. A parameter is these material models, especially since it is already complex
used to obtain the average temperature at the tool-chip interface, enough that a computer is required to carry out the calculations.
T a v e , from the maximum temperature rise, ⌬ m . For each as-
sumed shear plane angle, all of these calculations are carried out 3.2 Calculation of the Shear Plane Temperature. In Ox-
to find int , and the highest value of for which int ⫽k chi p is ley’s analysis the heat partition coefficient at the primary shear
taken to be the shear plane angle 关9兴. zone, , is calculated using the nondimensional number R T tan
The calculations above are repeated for various values of ␦, the evaluated at the average temperature along the shear plane, which
relative thickness of the secondary shear zone, to obtain the ␦ that depends on an arbitrary parameter . The overall temperature rise
Journal of Manufacturing Science and Engineering NOVEMBER 2003, Vol. 125 Õ 657
of the material in moving through the primary shear zone is found
using the total plastic work in the primary shear zone, accounting
for the heat conducted to the workpiece through the parameter .
It should be noted that the total power is calculated as F s V s , with
F s obtained from the material model for the temperature, strain
and strain rate corresponding to the midplane, not by the integra-
tion of the power required for deformation. The midplane tem-
perature is obtained by scaling the total temperature increase in
the primary shear zone with a parameter . Iteration through the
calculations is used to converge to the correct temperature at the
middle of the shear zone.
Using a slightly different approach, we calculate the tempera-
ture of the midpoint of the shear plane by equating the fraction 
of the total plastic work done up to the midplane of the primary
shear zone to the energy expended to increase the temperature of
the material. Point-wise evaluation of the properties of each of the
layers in the primary shear zone is used for the calculation. For
the Johnson-Cook material model the temperature of the shear
plane, T AB , is found from Fig. 2 Temperature variation along the thickness of the pri-
mary shear zone predicted by the modified model for Al 2024-
冕 T AB C p共 T 兲
冉 B
冊 T3. Cutting conditions: ␣Ä8°, t 1 Ä160 m, V Ä1.31 mÕs and b 1
冉
⫻ 1⫹C ln
˙ s
˙ 0 冊 (3)
tively. The average shear stress along the shear plane s is calcu-
where T w , the temperature of the lower part of the shear zone, is lated as the shear force divided by the shear plane area. In Oxley’s
assumed equal to the incoming workpiece material temperature, analysis, the shear strength of the material at the strain and tem-
the partition coefficient  is assumed to be constant and evaluated perature of the midpoint of the shear zone is taken to be the shear
at T AB , AB ⫽cos ␣/2冑3 cos(⫺␣)sin is the strain in the de- stress at the shear plane, from which the shear force is then cal-
formed material in the middle of the shear plane and ˙ s ⫽cV s /L is culated, without any guarantee that energy balance 共Eq. 共6兲兲 will
the strain rate in the primary shear zone assumed to be constant be satisfied. Figure 3 shows the variation of the shear strength
throughout the primary shear zone. The above equation can be through the thickness of the primary shear zone for Al 2024-T3.
solved iteratively or explicitly for T AB . The temperature of the Because of the competition between the temperature and strain
upper part of the shear zone, T EF , can be obtained in a similar there is a maximum in the shear strength along the shear zone.
manner as Also, the value of shear strength at the midplane is larger than the
冕 冉 冊
value of s obtained from the above energy balance.
T EF C p共 T 兲 B
冉 冊 m dT⫽ 共 1⫺  兲 A EF ⫹ n⫹1
TW T⫺T r n⫹1 EF
1⫺ 3.4 Calculation of the Hydrostatic Pressure at the Cutting
T m ⫺T r Edge and the Normal Stress on the Tool-Chip Interface.
冉
⫻ 1⫹C ln
˙ s
˙ 0 冊 (4)
From the equilibrium of the free surface near point A the hydro-
static pressure, p A , can be obtained as
冕
T
EF 兰 T EF C p 共 T 兲 dT
w
w⫽ d⫽ (5)
0 共 1⫺  兲
we can obtain the shear force, F s , in a consistent manner by
setting
F s V s ⫽wVt 1 b 1
(6) Fig. 3 Variation of shear strength along the thickness of the
F s wVt 1 primary shear zone predicted by the model for Al 2024-T3. Cut-
s⫽ ⫽ ting conditions: ␣Ä8°, t 1 Ä160 m, V Ä1.31 mÕs and b 1
As V sL
Ä4.7 mm. Note that the shear strength at the midplane of the
where V s is the shear velocity and V, t 1 and b 1 are the cutting shear zone, k AB , is different from the energy equivalent shear
velocity, undeformed chip thickness and workpiece width, respec- strength s .
冋 冉 冊
⫽tan⫺1 1⫹2
4
⫺ ⫺
c 共 k u ⫺k l 兲
2s 册 (9)
4 Results and Discussion
4.1 Comparison of Extended Model With Oxley’s Original
Model for 1020 Carbon Steel. We have developed a program
Knowing F s obtained from Eq. 共6兲, the normal and tangential using the Maple symbolic mathematics package to carry out this
components, N and F, of the resultant cutting force on the tool analysis. To verify the implementation of the model and to study
rake face can be obtained following Oxley as the effect of introducing the above changes into Oxley’s original
model for plain carbon steels we also implemented Oxley’s origi-
Fs nal model following the algorithm given by Oxley 关12兴 in all
N⫽ cos共 ⫺ ⫹ ␣ 兲
cos details. Figure 4 shows a comparison of the results of this imple-
(10)
mentation with the results published by Hastings et al. 关16兴 for
Fs 0.2% carbon steel under one particular set of cutting conditions. In
F⫽ sin共 ⫺ ⫹ ␣ 兲
cos all the graphs presented here experimental data points are marked
by symbols and lines represent the model predictions. It is ob-
The slip line field equation describing the relation between the
served that the correlation is very good, but not exact, especially
pressure at point B and the normal stress on the tool-chip interface
at low values of cutting speed. This may be attributed to uncer-
can be written in terms of s as
tainties in the exact values of particular parameters such as ,
n ⫽p B ⫹2 s 共 ⫺ ␣ 兲 (11) and c used by Hastings et al. to tune the model.
Figure 4 also compares the performance of the extended model
3.5 Calculations Pertaining to the Secondary Shear Zone. with that of Oxley’s original model. It can be seen that even
The length of contact 共H兲 along the tool-chip interface can be though we have eliminated the degree of freedom provided by the
obtained from moment equilibrium of the chip, using the same parameter , the predictions are slightly improved for cutting
approach adopted by Oxley 关12兴, as force and chip thickness. This is one of the main contributions of
冉 冊
the present work and may be attributed to the self-consistency of
b 1 L 2 2p A ⫹p B
H⫽ (12) the model and the imposition of energy balance in the primary
N 3 shear zone for calculation of the shear force.
where N is the normal force on the tool rake face.
Assuming uniform distribution of the normal force on the tool 4.2 Comparison of Extended Model With Experimental
rake face, the normal stress can be obtained as N/Hb 1 . Equating Data for Other Materials. We have used the extension of Ox-
this and n calculated from Eq. 共10兲, the parameter c can be ley’s analysis with the modifications described above to analyze
obtained as the machining of aluminum alloys 2024-T3, 6061-T6 and 6082-
c⫽
1
冋 N
冉
⫺ 1⫹ ⫺2 ␣
k l ⫺k u Hb 1 s 2 冊册 (13)
T6, 1045 steel and copper. The constants of the Johnson-Cook
material model for 1045 steel and Al 6082-T6 were obtained from
Jaspers 关25兴, for Al 2024-T3 from Johnson and Cook 关22兴 and for
Assuming sticking friction over the tool-chip interface, the av- 6061-T6 from Rule 关26兴. The coefficients A, B and n in the
erage value of the strain in the chip material can be considered to Johnson-Cook model were modified such that the model better
be represents the data obtained from compression of those materials
to high strains 关27,25兴. The modified constants of the Johnson-
␥˙ int H Cook material model for each of the materials used in this analy-
int ⫽ EF ⫹ (14)
冑3V c sis are listed in Table 1. The constants for the Maekawa’s material
model for 1045 steel and the MTS material model for copper were
in which ␥˙ int ⫽V c / ␦ t 2 is the average strain rate in the secondary obtained from Childs 关24兴 and Follansbee and Kocks 关28兴, respec-
shear zone and V c is the chip velocity. tively. These constants are listed in the appendix.
Stevenson and Oxley 关10兴 obtained Eq. 共15兲 below to represent The experimental data used in the comparison for Al 2024-T3
the results of Boothroyd’s numerical calculations for the ratio of and 6061-T6 were obtained by tube turning 关29兴. The Al 2024-T3
the mean temperature increase of the chip (⌬ c ) to the maximum tubes had a diameter of 70 mm and a wall thickness of 4.7 mm.
Journal of Manufacturing Science and Engineering NOVEMBER 2003, Vol. 125 Õ 659
Table 1 Constants for the Johnson-Cook material model for
the materials used in this study after adjusting to fit stress
strain curve obtained from compression test
Journal of Manufacturing Science and Engineering NOVEMBER 2003, Vol. 125 Õ 661
Fig. 7 „a… Comparison of the size effect predicted by the
model with the experimental data for Al 2024-T3 †29‡, and „b…
The decrease in specific cutting energy with increase in unde-
formed chip thickness can be attributed to the increase in
shear angle, caused by the increase in temperature at the tool-
chip interface and the consequent decrease in k chip . Cutting
conditions: ␣Ä8°, V Ä2.62 mÕs and b 1 Ä4.1 mm.
shear plane angle for cutting 1045 steel with different undeformed
chip thicknesses using different material models. The size effect
can again be seen in Fig. 11共a兲. It can also be seen that the
Johnson-Cook material model predicts the variation of the specific
cutting force more accurately compared to the Oxley material
model and the Maekawa material model, especially for the larger
undeformed chip thicknesses. It can be seen from Fig. 11共b兲 that
while all the models tend to underpredict the shear plane angle,
the Johnson-Cook material model leads to predictions closest to Fig. 8 Comparison of predicted „a… Cutting force, „b… Thrust
the experimental data. Note that in this case Oxley’s original force, and „c… Chip thickness with experimental data for Al
model predicts specific cutting force and the shear plane angle 6061-T6 †29‡. Cutting conditions: ␣Ä8°, b 1 Ä3.3 mm, different
better compared to the modified model with different material cutting speeds and undeformed chip thicknesses.
models but the difference is of the same order of magnitude as the
variation in the experimental data.
Figure 12 shows predictions of the cutting force and tempera- speed. Figure 12共b兲 shows the effect of cutting speed on the tool-
ture at the tool-chip interface for cutting 1045 steel with different chip interface temperature. The temperature was measured experi-
cutting speeds using different material models. As can be seen in mentally 关30兴 using the tool-work thermocouple technique. The
Fig. 12共a兲, the Johnson-Cook material model predicts the cutting measured values of temperature are between the maximum tem-
force most accurately. It can be noted that the cutting force pre- perature and the average temperature at the tool-chip interface.
dicted by the Maekawa material model is almost constant for dif- The experimental data is closer to the average temperature for the
ferent cutting speeds. Also, Oxley’s material model gives good Oxley and Maekawa material models, whereas it is closer to the
agreement with experimental data only for low values of cutting maximum temperature for the Johnson-Cook material model for
5 Conclusions
Oxley’s machining theory has been extended to use any of a
range of high strain rate constitutive models commonly used by
Fig. 9 Comparison of predicted „a… Cutting force, „b… Thrust the impact physics community and for which the constants are
force, and „c… Chip thickness with experimental data for Al available for a wide range of materials. In the process, changes
6082-T6 †25‡. Cutting conditions: ␣Ä8°, different cutting speeds have been made to the theory to improve its self-consistency. The
and undeformed chip thicknesses. extended model has been used to analyze the machining of steel,
aluminum and copper. The model predicts all experimentally ob-
served trends well, which is quite remarkable considering the fact
higher cutting velocities. It can also be seen that temperatures that the model parameters are typically obtained from experiments
predicted by Maekawa’s material model are more sensitive with at much lower values of strain, strain rate and temperature than
respect to the cutting speed and follow the trend in experimental that encountered in machining. Among different material model
data more closely compared to the other material models. It used the Johnson-Cook and Maekawa’s material models perform
should be noted that Stephenson 关32兴 found that the temperature best in terms of prediction of cutting forces and temperature re-
Journal of Manufacturing Science and Engineering NOVEMBER 2003, Vol. 125 Õ 663
Fig. 12 Comparison predicted „a… Cutting force, and „b… Tem-
Fig. 11 Comparison of predicted „a… Specific cutting force, perature of the tool-chip interface using different material mod-
and „b… Shear plane angle using different material models with els with Oxley’s original model †31‡ and experimental data †30‡
Oxley’s original model †12‡ and experimental data †12‡ for for 0.45% carbon steel. Cutting conditions: ␣Ä5°, t 1 Ä0.2 mm,
0.45% carbon steel. Cutting conditions: ␣ÄÀ5°, V Ä7 mÕs and b 1 Ä3 mm and different cutting speeds. Oxley’s original model
different undeformed chip thicknesses. Oxley’s original model underpredicts both cutting force and temperature along the
performs better compared to modified model with different ma- tool-chip interface. The Johnson-Cook and Maekawa material
terial models. Among different material models used the models perform better in prediction of the cutting force and
Johnson-Cook material model shows the most sensitivity with temperature respectively.
respect to changes in undeformed chip thickness.
Journal of Manufacturing Science and Engineering NOVEMBER 2003, Vol. 125 Õ 665
s is a function of strain rate and temperature. The specific form of 关7兴 Fang, N., Jawahir, I. S., and Oxley, P. L. B., 2001, ‘‘A Universal Slip-Line
the mechanical threshold model used in this study can be written Model With Non-Unique Solutions for Machining With Curled Chip Forma-
as 关28兴 tion and a Restricted Contact Tools,’’ Int. J. Mech. Sci., 43, pp. 557–580.
再 冋 册冎
关8兴 Hill, R., 1954, ‘‘The Mechanics of Machining: A New Approach,’’ J. Mech.
1/q 1/p Phys. Solids, 3, pp. 47–53.
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⫽ ˆ a ⫹ 共 ˆ ⫺ ˆ a 兲 1⫺ (16)
g 0 b 3 Machining: Allowing for the Effects of Strain-Rate and Temperature on Tool-
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threshold stress, ˆ , temperature, T, and strain rate ˙ . k is the tigation of the Influence of Speed and Scale on the Strain-Rate in a Zone of
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is the shear modulus, b is the magnitude of the Burgers vector, Zone of Intense Shear in Which the Chip is Formed in Machining From the
and p and q are constants that represent the energy profile of Dynamic Flow Stress Properties of the Work Material and the Cutting Condi-
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冋 冊冊 册
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d ˆ
⫽ 0 1⫺
tanh 2 冉冉 ˆ ⫺ ˆ a
ˆ s ⫺ ˆ a
(17)
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˙ so
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3
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˙
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M ⫹m 1
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