This paper presents analytical predictions and experimental validation of a recently developed universal slip-line model for machining with restricted contact cut-away tools. Three important machining parameters, i.e. the cutting force ratio, chip thickness, and chip back-flow angle, are predicted on the basis of: (1) the universal slip-line model; (2) a maximum value principle for determining the state of stresses in the plastic region in restricted contact machining; (3) Dewhurst and Collins' matrix technique for numerically solving slip-line problems; and (4) Powell's algorithm for non-linear optimizations. All predictions are based on purely theoretical calculations with no experimental/empirical data as input. The extensive comparisons between theory and experiments show a reasonable agreement. Major new research findings from this study include: (1) the applicable ranges of an extreme friction slip-line model and of Johnson's and Usui and Hoshi's slip-line models; and (2) the general rule of the variation of tool-chip friction conditions. Tool-chip contact in machining with restricted contact cut-away tools is categorized into three broad cases. A theoretical method is also presented in the paper to distinguish different tool-chip contact cases in practical machining situations.
|Number of pages||14|
|Journal||International Journal of Machine Tools and Manufacture|
|State||Published - May 2002|
Bibliographical noteFunding Information:
The research support for this work provided by the National Science Foundation (NSF Grant: DMII-9713932) and the Center for Robotics and Manufacturing Systems at the University of Kentucky is gratefully acknowledged.
- Chip back-flow angle
- Chip thickness
- Cutting force ratio
- Universal slip-line model
ASJC Scopus subject areas
- Mechanical Engineering
- Industrial and Manufacturing Engineering