Energy Dissipation and Tool-Workpiece Contact in Ultra-Precision Machining

Effect of finite edge radius on ductile fracture ahead of the cutting tool edge in micro-cutting of Al2024-T3

“…The ploughing mechanism has been attributed to the observed increase in machining forces with tool edge radius and attempts have been made to isolate the ploughing force by extrapolating the forces to zero uncut chip thickness [20]. The effect of tool edge geometry on the force and energy decomposition have been reported in [10]. This experimental study showed that the nominal rake angle and the tool edge profile significantly affect the forces.…”

“…The extra plastic flow associated with a non-zero edge radius has also been considered as a reason for the size effect [10][11][12]. Cutting tools commonly used in machining operations are never ideally sharp but always have some bluntness.…”

Integrated approach to advanced machining

“…This assumption was also made by L~c c a and Seo [8] and our method of analysis is identical to the one described in their paper. In addition to this basic assumption, it is assumed that plane strain conditions apply (which is exactly what the orthogonal cutting geometry is attempting to achieve) and that the material is elastic-perfectly plastic, i.e.…”

“…8 GPa, E = 124 GPa and k = 1 GPa. The coefficient of friction, pf, was determined by taking a decreasing depth of cut on an unheat-treated ling.…”

A method to include plastic anisotropy to orthogonal micromachining of fcc single crystals

“…Lucca developed a sliding indentation model and estimated subsurface damage for aluminum to be 0.31-0.81 μm for cut depths of 0.1-1 μm, respectively, that match with the X-ray measurements [32]. Moriwaki and Okuda [25] observed that, below a 0.2-μm depth of cut, rubbing and burnishing become more dominant than shear and no crystallographic effect is found while machining polycrystal copper.…”