Application of Computational Machining Method to Discontinuous Chip Formation

Author:

Obikawa T.1,Sasahara H.1,Shirakashi T.1,Usui E.2

Affiliation:

1. Department of Mechano-Aerospace Engineering, Tokyo Institute of Technology, 2-12-1 Ohokayama, Meguro-ku, Tokyo 152, Japan

2. Department of Mechanical Engineering, Tokyo Denki University, 2-2 Kanda-nishikicho, Chiyoda-ku, Tokyo 101, Japan

Abstract

A finite element modeling is developed to simulate and visualize the discontinuous chip formation in the orthogonal cutting of 60 percent Cu-40 percent Zn brasses. A ductile fracture criterion expressed as a function of strain, strain rate and hydrostatic pressure is applied to the crack growth from the tool tip to the chip free surface in the segmentation of discontinuous chips. Chip shape and the inclination of fracture surface produced in computational machining are in good agreement with those in actual machining. The visualization of the computational machining processes clarifies the mechanism of discontinuous chip formation. The influences of chip segmentation upon the residual stress and strain in the machined layer are also clarified quantitatively.

Publisher

ASME International

Subject

Industrial and Manufacturing Engineering,Computer Science Applications,Mechanical Engineering,Control and Systems Engineering

Reference26 articles.

1. Bridgeman, P. W., 1964, Studies in Large Plastic Flow and Fracture, Harvard University Press, Cambridge.

2. Cook N. H. , FinnieI., and ShawM. C., 1954, “Discontinuous Chip Formation,” Transactions of the ASME, Vol. 76, pp. 153–162.

3. Field M. , and MerchantM. E., 1949, “Mechanics of Formation of the Discontinuous Chip in Metal Cutting,” Transactions of the ASME, Vol. 71, pp. 421–428.

4. Komanduri R. , and von TurkovichB. F., 1981, “New Observations on the Mechanisms of Chip Formation When Machining Titanium Alloys,” Wear, Vol. 69, pp. 179–188.

5. Komanduri R. , and SchroederT. A., 1986, “On Shear Instability in Machining a Nickel-Iron Base Superalloy,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY, Vol. 108, pp. 93–100.

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