Experimental and analytical investigation on mechanics of metal cutting including edge forces

Official URL: http://192.168.1.20/record=b1226356 (Table of Contents)

Almost every field of industry requires machining in their processes. Products are mass manufactured from a sequence of machining operations in certain amount of time. In this material removal processes metal cutting is the most common one. The main purpose is to shape metals and alloys by using chip formation operations and any improvement in the cycle time will reduce the total cost significantly. Therefore, modeling of the machining operations such as turning and milling is very important in terms of process effectiveness. In accordance with the technological developments and computer integration, the modeling of the metal cutting processes becomes easier. Depending on the application, machining type may differ; however the basic principles remain the same. In this respect, mechanics and the dynamics of the orthogonal cutting model provide invaluable insight regarding the selection of process parameters. In this thesis, the mechanics of orthogonal and oblique cutting is reviewed using analytical and experimental methods for different materials and process conditions. The results are used in mechanistic modeling of the cutting forces and predicted cutting forces are compared with the experimental results. As an important part of the experimental work, edge forces are also analyzed empirically. The effect of hone radius on the cutting process is investigated, and taken into account in force predictions using an analytical model proposed by Ozlu [20], and promising results are obtained and verified by experiments.