Analytical modeling of cutting process mechanics and dynamics for simulation of industrial machining operations

Official URL: http://192.168.1.20/record=b1276326 (Table of Contents)

Machining has been one of the most widely used manufacturing methods since the industrial revolution. Although the technological developments enabled machine tools to be stronger, work faster and produce more precise parts, the process parameters are still selected based on the experience. Selection of the acceptable or optimum parameters can only be possible by conducting extensive amount of experiments or by the help of the process models. The main aim of this thesis is to develop analytical models in order to represent the true mechanical and dynamical behavior of metals during cutting operations. Analytical models for the orthogonal and oblique cutting processes are proposed. These models are used as a base in order to simulate commonly used industrial operations such as turning and 5 axis milling. Moreover, an initial approach is proposed in order to model cutting behavior when the cutting tool has a hone radius. The proposed models are step ahead from the previous ones as they represent the rake face contact and friction in a more accurate manner, and have the ability to calibrate the material model parameters and friction by few tests. The dynamic behavior during cutting is also a very important aspect. For this, a stability model which includes multi-dimensional nature of the cutting process is proposed. All the proposed models are verified by experiments and overall good agreement is observed. These models can be applied to industrial machining operations yielding shorter machining times, better surface quality, longer tool life, stable operations and less manufacturing costs.