A universal slip-line model and the corresponding hodograph for two-dimensional machining which can account for chip curl and chip back-flow when machining with a restricted contact tool are presented in this paper. Six major slip-line models previously developed for machining are briefly reviewed. It is shown that all the six models are special cases of the universal slip-line model presented in this paper. Dewhurst and Collins's matrix technique for numerically solving slip-line problems is employed in the mathematical modeling of the universal slip-line field. A key equation is given to determine the shape of the initial slip-line. A non-unique solution for machining processes when using restricted contact tools is obtained. The influence of four major input parameters, i.e. (a) hydrostatic pressure (PA) at a point on the intersection line of the shear plane and the work surface to be machined; (b) ratio of the frictional shear stress on the tool rake face to the material shear yield stress (τ/k); (c) ratio of the undeformed chip thickness to the length of the tool land (t1/h); and (d) tool primary rake angle (γ1), upon five major output parameters, i.e. (a) four slip-line field angles (θ, η1, η2, ψ); (b) non-dimensionalized cutting forces (Fc/kt1 w and Ft/kt1 w); (c) chip thickness (t2); (d) chip up-curl radius (Ru); and (e) chip back-flow angle (ηb), is theoretically established. The issue of the `built-up-edge' produced under certain conditions in machining processes is also studied. It is hoped that the research work of this paper will help in the understanding of the nature and the basic characteristics of machining processes.
|Number of pages||24|
|Journal||International Journal of Mechanical Sciences|
|State||Published - Feb 2001|
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.
ASJC Scopus subject areas
- Civil and Structural Engineering
- Materials Science (all)
- Condensed Matter Physics
- Mechanics of Materials
- Mechanical Engineering