A slip-line model for serrated chip formation in machining of stainless steel and validation

Alper Uysal, I. S. Jawahir

Research output: Contribution to journalArticlepeer-review

13 Scopus citations

Abstract

Machining of difficult-to-cut materials producing serrated chip formation has generated a significant interest among academic researchers and industry groups because of the need for understanding the fundamental mechanisms to model the process. Therefore, various analytical and numerical models have been developed in the recent past to investigate such machining operations. The slip-line theory is one of the established modeling methods, but slip-line modeling of serrated chip formation has not been investigated adequately. In this study, a new slip-line model for serrated chip formation in machining with rounded cutting edge tool is presented along with its associated hodograph. In addition, Oxley’s theory was integrated to the proposed slip-line model for stainless steel material, and the model was validated by experimental results. A good agreement between the experimental and analytically predicted results was obtained. The proposed slip-line model offers predictions of cutting and thrust forces, ploughing force, maximum and minimum chip thickness values, tool–chip contact length, chip up-curl radius, thickness of the primary shear zone, angular position of the stagnation point, shear strain, shear strain rate at the shear plane, and the prevalent flow stress.

Original languageEnglish
Pages (from-to)2449-2464
Number of pages16
JournalInternational Journal of Advanced Manufacturing Technology
Volume101
Issue number9-12
DOIs
StatePublished - Apr 19 2019

Bibliographical note

Funding Information:
Acknowledgements Alper Uysal acknowledges financial support from the Scientific and Technological Research Council of Turkey (TUBİTAK) BIDEB-2219 Postdoctoral Research Program.

Publisher Copyright:
© 2018, Springer-Verlag London Ltd., part of Springer Nature.

Keywords

  • Oxley’s theory
  • Serrated chip
  • Slip-line model
  • Stainless steel

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Software
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

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