Experimental investigation and force modeling of orthogonal cutting with the effect of third deformation zone

Official URL: http://192.168.1.20/record=b1558938 (Table of Contents)

Metal cutting is the most common manufacturing method used in various industries. There have been many investigations on the interaction between the cutting edge and the material in the first and the second deformation zones in order to understand the mechanics of the process. Investigations on the third deformation zone, on the other hand, have been limited although it may have significant effects on the process and the machined part. Especially in finishing operations where slow feed rates are used, the contributions of the edge and flank contacts on the total cutting force can be substantial. Furthermore, the third zone determines the surface quality and the integrity due to its direct contact with the finished surface. Despite of these important effects of the third zone, there is lack of analytical and practical methods for modeling and predictions of the third deformation zone in metal cutting which is the focus of the thesis. In this study, an experimental analysis of cutting forces along with the thermal investigation of third deformation zone is presented. An orthogonal cutting model including a thermo-mechanical model with sticking and sliding contact zones is developed in order to determine the effects of hone radius and flank contact on cutting forces. Different approaches such as full and elastic recovery of the material are considered for contact length calculations. Predictions of the proposed model are compared with the measurements and. it is shown that the model predictions are reasonably comparable to the experimental data with close trends.