On the steady-state workpiece flow mechanism and force prediction considering piled-up effect and dead metal zone formation
(2021) In Journal of Manufacturing Science and Engineering 143(4).- Abstract
The manufacturing of miniaturized components is indispensable in modern industries, where the uncut chip thickness (UCT) inevitably falls into a comparable magnitude with the tool edge radius. Under such circumstances, the ploughing phenomenon between workpiece and tool becomes predominant, followed by the notable formation of dead metal zone (DMZ) and piled-up chip. Although extensive models have been developed, the critical material flow status in such microscale is still confusing and controversial. In this study, a novel material separation model is proposed for the demonstration of workpiece flow mechanism around the tool edge radius. First, four critical positions of workpiece material separation are determined, including three... (More)
The manufacturing of miniaturized components is indispensable in modern industries, where the uncut chip thickness (UCT) inevitably falls into a comparable magnitude with the tool edge radius. Under such circumstances, the ploughing phenomenon between workpiece and tool becomes predominant, followed by the notable formation of dead metal zone (DMZ) and piled-up chip. Although extensive models have been developed, the critical material flow status in such microscale is still confusing and controversial. In this study, a novel material separation model is proposed for the demonstration of workpiece flow mechanism around the tool edge radius. First, four critical positions of workpiece material separation are determined, including three points characterizing the DMZ pattern and one inside considered as stagnation point. The normal and shear stresses as well as friction factors along the entire contact region are clarified based on slip-line theory. It is found that the friction coefficient varies symmetrically about the stagnation point inside DMZ and remains constant for the rest. Then, an analytical force prediction model is developed with Johnson-Cook constitutive model, involving calibrated functions of chip-tool contact length and cutting temperature. The assumed tribology condition and morphologies of material separation including DMZ are clearly observed and verified through various finite element (FE) simulations. Finally, comparisons of cutting forces from cutting experiments and predicted results are adopted for the validation of the predictive model.
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- author
- Hu, Cheng ; Zhang, Weiwei ; Zhuang, Kejia ; Zhou, Jinming LU and Ding, Han
- organization
- publishing date
- 2021-04-01
- type
- Contribution to journal
- publication status
- published
- subject
- keywords
- Cutting force, Dead metal zone, Machining processes, Material separation, Piled-up effect, Rounded-edge, Tribology in manufacturing
- in
- Journal of Manufacturing Science and Engineering
- volume
- 143
- issue
- 4
- article number
- 041009
- publisher
- American Society Of Mechanical Engineers (ASME)
- external identifiers
-
- scopus:85107691775
- ISSN
- 1087-1357
- DOI
- 10.1115/1.4048952
- language
- English
- LU publication?
- yes
- id
- 4c5f8b06-fe0a-4939-aeb4-f1121e2365db
- date added to LUP
- 2021-06-29 14:02:42
- date last changed
- 2022-05-02 08:44:32
@article{4c5f8b06-fe0a-4939-aeb4-f1121e2365db,
abstract = {{<p>The manufacturing of miniaturized components is indispensable in modern industries, where the uncut chip thickness (UCT) inevitably falls into a comparable magnitude with the tool edge radius. Under such circumstances, the ploughing phenomenon between workpiece and tool becomes predominant, followed by the notable formation of dead metal zone (DMZ) and piled-up chip. Although extensive models have been developed, the critical material flow status in such microscale is still confusing and controversial. In this study, a novel material separation model is proposed for the demonstration of workpiece flow mechanism around the tool edge radius. First, four critical positions of workpiece material separation are determined, including three points characterizing the DMZ pattern and one inside considered as stagnation point. The normal and shear stresses as well as friction factors along the entire contact region are clarified based on slip-line theory. It is found that the friction coefficient varies symmetrically about the stagnation point inside DMZ and remains constant for the rest. Then, an analytical force prediction model is developed with Johnson-Cook constitutive model, involving calibrated functions of chip-tool contact length and cutting temperature. The assumed tribology condition and morphologies of material separation including DMZ are clearly observed and verified through various finite element (FE) simulations. Finally, comparisons of cutting forces from cutting experiments and predicted results are adopted for the validation of the predictive model.</p>}},
author = {{Hu, Cheng and Zhang, Weiwei and Zhuang, Kejia and Zhou, Jinming and Ding, Han}},
issn = {{1087-1357}},
keywords = {{Cutting force; Dead metal zone; Machining processes; Material separation; Piled-up effect; Rounded-edge; Tribology in manufacturing}},
language = {{eng}},
month = {{04}},
number = {{4}},
publisher = {{American Society Of Mechanical Engineers (ASME)}},
series = {{Journal of Manufacturing Science and Engineering}},
title = {{On the steady-state workpiece flow mechanism and force prediction considering piled-up effect and dead metal zone formation}},
url = {{http://dx.doi.org/10.1115/1.4048952}},
doi = {{10.1115/1.4048952}},
volume = {{143}},
year = {{2021}},
}