Sage Journals: Discover world-class research

Abstract

In the high speed machining of metals it has been established that the shearing process is frequently non-uniform resulting in a serrated chip with highly localised shearing. This type of chip formation is promoted solely by the properties of the material being machined and is not initiated by vibrations or resonances of the machine structure. It has been found that this type of unsteady, shear localised chip form can be duplicated when polyethylene is machined at low speeds with araldite cutting tools. By means of a photoelastic technique the variations in tool stress associated with these non-uniform chip forms has been revealed during the machining process. The photoelastic results clearly show that the tool stresses oscillate in a regular manner during the formation of each chip segment. The results obtained have lead to a better understanding of the chip formation process and provide a more complete description of the stress conditions experienced by the cutting tool.

Get full access to this article

View all access options for this article.

References

Komanduri

‘Highlights of the DARPA advanced machining research programme’, Trans. ASME, J. Engng Ind., 1985, 107, 325–335.

Lemaire

J. C.

Backofen

W. A.

‘Adiabatic instability in the orthogonal cutting of steel’, Met. Trans, 1972, 3, 477–481.

Ueda

Matsuo

‘An analysis of saw-toothed chip formations’, Ann. CIRP, 1982, 31/1, 81–84.

Lee

‘The effect of cutting speed on chip formation under orthogonal machining’, J. Engng Ind., 1985, 107, 55–62.

Recht

R. F.

‘Catastrophic thermoplastic shear’, J. Appl. Mech., 1964, 32, 189.

Shaw

M. C.

‘The assessment of machinability’, Machinability, ISI Special Report No. 94, October 1965.

Arndt

‘Ultra-high-speed machining: A review and analysis of cutting forces’, Proc. Instn mech. Engrs, 1973, 187, 625.

Komanduri

‘On the catastrophic shear instability in high speed machining of an AISI 4340 steel’, J. Engng Ind., 1982, 104, 121–131.

Komanduri

Hazra

‘A metallurgical investigation of chip morphology in machining an AISI 4340 steel at various speeds up to 10 100 sfpm’, Proc. 9th NAMRC, 1981, pp. 356–373.

10.

Komanduri

Von Turkovich

B. F.

‘New observations on the mechanism of chip formation when machining titanium alloys’, Wear, 1981, 69, 179–188.

11.

Komanduri

‘Some clarifications on the mechanics of chip formation when machining titanium alloys’, Wear, 1982, 76, 15–34.

12.

Komanduri

Schroeder

T. A.

‘On shear instability in machining a nickel-iron based superalloy’, J. Engng Ind. 1986, 108, 93–100.

13.

Coker

E. G.

Chakko

K. C.

‘Experiments on the action of cutting tools’, Proc. Instn mech. Engrs, 1922, 567–621.

14.

Usui

Takeyama

‘A photoelastic analysis of machining stresses’, J. Engng Ind., 1960, 82, 303–308.

15.

Amini

‘A technique for automatic recording of photoelastic data applied to steady and dynamic cutting’, J. Strain Analysis, 1968, 3, 200–205.

16.

Amini

‘Photoelastic analysis of stresses and forces in steady cutting’, J. Strain Analysis, 1968, 3, 206–213.

17.

Loladze

T. N.

‘Nature of brittle failure of cutting tools’, Ann. CIRP, 1975, 24, 13–16.

18.

Chandrasekaran

Nagarajan

‘Influence of flank wear on the stresses in a cutting tool’, J. Engng Ind., 1977, 99, 566–577.

19.

Yamamoto

‘Proposal of stress distribution models on rake surface in orthogonal cutting’, J. Japan Soc. Prec. Engng, 1979, 45, 1370–1375.

20.

Nakamura

‘A study of the wide variation of tool life owing to engagement angle’, Bull. Japan Soc. Prec. Engng, 1982, 16, 231–236.

21.

Bagchi

Photoelastic stress analysis in machining using sapphire tools, PhD thesis, Carnegie-Mellon University, 1983.

22.

KUSKE, A. and ROBERTSON, G., Photoelastic stress analysis, 1974 (John Wiley, New York).

23.

Metals Handbook, 9th Edition, 1978 (American Society of Metals), Vol. 3, pp. 448–465.

A photoelastic study of tool stresses caused by unsteady,shear localised chip formations during machining

Abstract

Abstract

Get full access to this article

References