Commenced in January 2007
Paper Count: 30831
Mathematical Modeling Experimental Approach of the Friction on the Tool-Chip Interface of Multicoated Carbide Turning Inserts
Abstract:The importance of machining process in today-s industry requires the establishment of more practical approaches to clearly represent the intimate and severe contact on the tool-chipworkpiece interfaces. Mathematical models are developed using the measured force signals to relate each of the tool-chip friction components on the rake face to the operating cutting parameters in rough turning operation using multilayers coated carbide inserts. Nonlinear modeling proved to have high capability to detect the nonlinear functional variability embedded in the experimental data. While feedrate is found to be the most influential parameter on the friction coefficient and its related force components, both cutting speed and depth of cut are found to have slight influence. Greater deformed chip thickness is found to lower the value of friction coefficient as the sliding length on the tool-chip interface is reduced.
Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1057721Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2722
 V.P. Astakhov, "On the inadequacy of the single-shear plane model of chip formation," International Journal of Mechanical Sciences, vol. 47, pp. 1649-1672, 2005.
 F. Zemzemi et al., "Development of a friction model for the tool-chipworkpiece interfaces during dry machining of AISI4142 steel with TiN coated carbide cutting tools," Int. J. Machining and Machinability of Materials, vol. 2, no. 3, pp. 361-377, 2007.
 E. Merchant, "Mechanics of the Metal Cutting Process I. Orthogonal Cutting and a Type 2 Chip," Journal of Applied Physics, vol. 16, no. 5, pp. 267-275, 1945.
 J. D. Cumming, S. and E. G. Thomsen, "A New Analysis of the Forces in Orthogonal Metal Cutting," ASME J. Eng. Ind., vol. 87, pp. 480-486, 1965.
 N. N. Zorev, "Inter-relationship between shear processes occurring along tool face and shear plane in metal cutting," International Research in Production Engineering, ASME, New York, pp. 42-49, 1963.
 E.H. Lee and B.W. Shaffer, "The Theory of plasticity applied to a problem of machining," Trans. ASME, J. Appl. Mech., vol. 18, pp. 405- 413, 1951.
 M. C. Shaw, N.H. Cook, and I. Finnie, "The Shear-Angle Relationship in Metal Cutting," Transaction ASME, vol. 75, pp. 273-283, 1953.
 W. B. Palmer and P. L. B. Oxley, "Mechanics of Orthogonal Machining," Proc. Instn. Mech. Engrs., vol. 173, no. 24, pp. 623-638, 1959.
 C. Kilicaslan, "Modelling and simulation of metal cutting by finite element method," A M.Sc. thesis, Graduate School of Engineering and Sciences of Izmir Institute of Technology, December 2009 ─░ZM─░R, Turkey.
 E. Ozlu and E. Budak, "Experimental Analysis and Modeling of Orthogonal Cutting Using Material and Friction Models," in 4th International Conference and Exhibition on Design and Production of MACHINES and DIES/MOLDS, Cesme, 2007, TURKEY, p. 23.
 V.P. Astakhov, "Editorial: tribology at the forefront of study and research on metal cutting," Int. J. Machining and Machinability of Materials, vol. 2, no. 3, pp. 309-313, 2007.
 B. Titus, B. Watmon and C. Anthony, "Coating Cutting Tools with Hard Substance Lowers Friction Coefficient and Improves Tool Life - A Review," in Proceedings of the International MultiConference of Engineers and Computer Scientists 2010, vol. III, IMECS 2010, Hong KONG, March 17-19, 2010.
 S. Jacobson, S, Wallén P, Hogmark, S, "Intermittent metal cutting at small cutting depths Cutting forces," International Journal of Machine Tools and Manufacture, vol. 28, no. 4, pp. 551-567, 1988.
 P. Wallén and S. Hogmark, "Influence of TiN coating on wear of high speed steel at elevated temperature," Journal of Wear, vol. 130, no. 1, pp. 123-135, 1989.
 M. C. Shaw, "Metal cutting Principles," Oxford University Press, 2nd Ed, 2005.
 S. A. Iqbal, P. T. Mativenga and M. A. Sheikh, "Contact length prediction: mathematical models and effect of friction schemes on FEM simulation for conventional to HSM of AISI 1045 steel," Int. J. Machining and Machinability of Materials, vol. 3, nos. 1/2, pp. 18-33, 2008.
 P. Hedenqvist, M. Olsson, P. Wallén, A., Kassman, S. Hogmark and S. Jobson, "How TiN coatings improve the performance of high speed steel cutting tools," Journal of Surface and Coatings Technology, vol. 41, no. 2, pp. 243-256, 1990.
 V. P. Astakhov, "Tribology of Metal Cutting," London: Elsevier, 2006.
 Tugrul Ozel, "The influence of friction models on finite element simulations of machining," International Journal of Machine Tools & Manufacture, vol. 46, pp. 518-530, 2006.
 E. Usui, and H. Takeyama, "A Photoelastic Analysis of Machining Stress", Trans ASME, J. Eng. Industry, pp. 303-308, 1960.
 V. Madhavan, S. Chandrasekar and T. N. Farris, ÔÇÿDirect observation of the chip-tool interface in the low speed cutting of pure metals," Transactions of the ASME, Journal of Tribology, vol. 124, pp. 617-626, 2002.
 B. Ackroyd, S. Chandrasekar and W. D. Compton, "A model for the contact conditions at the chip-tool interface in machining", Transaction of ASME, Journal of Tribology, vol. 125, pp. 649-660, 2003.
 G. Dieter, "Mechanical metallurgy," New York, McGraw-Hill, 1976.
 M. Y. Friedman and E. Lenz, "Investigation of the tool-chip contact length in metal cutting," International Journal of Machine Tools Design, vol. 10, pp. 401-416, 1970.
 S. A. Iqbal, P. T. Mativenga and M. A. Sheikh, "Characterization of the Machining of AISI 1045 steel over a wide range of cutting speeds-Part 1: Investigation of contact phenomena," Proceedings of IMechE Part B: Journal of Engineering Manufacture, vol. 221, no. 5, pp. 909-916, 2007.
 M. Shatla, C. Kerk and T. Altan, "Process Modelling in Machining. Part II: Validation and Applications of the Determined Flow Stress Data," International Journal of Tools and Manufacturing, vol. 41, pp. 1659- 1680, 2001.
 S. E. Oraby and A. M. Alaskari, "On the Variability of Tool Wear and Life at Disparate Operating Parameters," Kuwait Journal of Science & Engineering (KJSE), An International Journal of Kuwait University, vol. 35, no. 1B, 2008.
 S.E. Oraby, E.A. Almeshaiei and A. ALASKARI, "Adaptive control simulation approach based on mathematical model optimization algorithm for rough turning," Kuwait Journal of Science & Engineering (KJSE), An International Journal of Kuwait University, vol. 30, no. 2, pp. 213-234, 2003.
 R. N. Arnold, "The Mechanism of Tool Vibration in Cutting of Steel," Proc. Inst. Mech. Engrs., vol. 27, pp. 261-276, 1946.
 A. M. Bakkal, et al., "Chip formation, cutting forces, and tool wear in turning of Zr-based bulk metallic glass," International Journal of Machine Tools & Manufacture, vol. 44, pp. 915-925, 2004.