Analytical Prediction of Three Dimensional Cutting Process—Part 1: Basic Cutting Model and Energy Approach

Abstract

The paper proposes a new model of chip forming process in three dimensional cutting with single point tool, in which the process is interpreted as a piling up of orthogonal cuttings along the cutting edge. Based upon the proposed model, an energy method similar to the upper bound approach, which enables to predict the chip formation and the three components of cutting force by using only the orthogonal cutting data, is developed. The method is also applied to predict chip formation and cutting force in oblique cutting, plain milling, and groove cutting operations.

Thermoelastic plastic metals with mass diffusion

“…Klamecki [12] formulated a three dimensional elasticplastic model to study the chip formation, while Usui et al [13] and Lajczok [14] applied finite element methods with an Eulerian formulation to simulate metal cutting. Strenkowski and Carrol [15] introduced the application of a finite element program (NIKE2D) with an updated Lagrangian formulation and proposed an element separation criterion to simulate the chip formulation process.…”

Experimental and Theoretical Analysis of the Chip Flow Direction in Turning using Flatted and Grooved Inserts – Impact of the Tool Rake Face Geometry, the Work Material and Cutting Conditions

“…As input data of the model, they use thermomechanical parameters of the tool and workpiece materials. Strenkowski et al [11] proposed a combined analytical-numerical model, based on Usui's energy model (Usui et al, [12]; Usui and Hirota, [13]) for the analytical calculation and Eulerian finite element model for the numerical calculation. Usui's energy model is based on the minimisation of shear and friction energies to find the chip flow angle.…”

Mechanistic Force Modeling for Broaching Process

“…The values of specific cutting energy constants can be determined using a simple calibration experiment [17][18][19]. The experiments were conducted for shaping operation and specific cutting energy constants are determined.…”