EXPERIMENTAL INVESTIGATION AND FORCE MODELING OF ORTHOGONAL CUTTING WITH THE EFFECT OF THIRD DEFORMATION ZONE
Industrial Engineering, MSc. Thesis, 2014
Prof. Dr Erhan Budak (Thesis Supervisor), Assoc. Prof. Dr. Bahattin Koç, Assoc. Prof. Dr. Ali Koşar
Date & Time: January 13th, 2014 – 11.00 AM
Place: FENS L062
Keywords : Orthogonal Cutting, Hone radius, Edge Forces, Machining Process Modeling
The third deformation zone in metal cutting operations may have significant effects on the process and machined part. Especially in finishing operations where slow feed rates are used, the contributions of the edge hone and flank contact forces on the total cutting force can be substantial. Furthermore, the third zone determines the surface quality and the integrity due to the direct contact with the finished surface. Despite of these important effects of the third zone, it has been relatively less investigated, and there is lack of analytical and practical methods for modeling and predictions. In this study, an experimental analysis of cutting forces along with the thermal investigation of third deformation zone is presented; and an orthogonal cutting model is developed in order to determine the effect of the hone radius and flank contact on the cutting forces. A thermo-mechanical model with sticking and sliding contact zones is adopted for force calculations whereas different approaches such as full recovery and elastic recovery of the material on the flank contact is taken into consideration for contact length calculations. Proposed model is compared with the experimental studies are presented. Also optimization of the dual zone model, pressure distribution and contact length are discussed.