Mathematical Modeling Experimental Approach of the Friction on the Tool-Chip Interface of Multicoated Carbide Turning Inserts
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.
[1] 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.
[2] 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.
[3] 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.
[4] 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.
[5] 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.
[6] 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.
[7] M. C. Shaw, N.H. Cook, and I. Finnie, "The Shear-Angle Relationship
in Metal Cutting," Transaction ASME, vol. 75, pp. 273-283, 1953.
[8] W. B. Palmer and P. L. B. Oxley, "Mechanics of Orthogonal
Machining," Proc. Instn. Mech. Engrs., vol. 173, no. 24, pp. 623-638,
1959.
[9] 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.
[10] 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.
[11] 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.
[12] 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.
[13] 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.
[14] 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.
[15] M. C. Shaw, "Metal cutting Principles," Oxford University Press, 2nd
Ed, 2005.
[16] 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.
[17] 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.
[18] V. P. Astakhov, "Tribology of Metal Cutting," London: Elsevier, 2006.
[19] 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.
[20] E. Usui, and H. Takeyama, "A Photoelastic Analysis of Machining
Stress", Trans ASME, J. Eng. Industry, pp. 303-308, 1960.
[21] 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.
[22] 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.
[23] G. Dieter, "Mechanical metallurgy," New York, McGraw-Hill, 1976.
[24] 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.
[25] 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.
[26] 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.
[27] 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.
[28] 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.
[29] R. N. Arnold, "The Mechanism of Tool Vibration in Cutting of Steel,"
Proc. Inst. Mech. Engrs., vol. 27, pp. 261-276, 1946.
[30] 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.
[1] 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.
[2] 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.
[3] 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.
[4] 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.
[5] 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.
[6] 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.
[7] M. C. Shaw, N.H. Cook, and I. Finnie, "The Shear-Angle Relationship
in Metal Cutting," Transaction ASME, vol. 75, pp. 273-283, 1953.
[8] W. B. Palmer and P. L. B. Oxley, "Mechanics of Orthogonal
Machining," Proc. Instn. Mech. Engrs., vol. 173, no. 24, pp. 623-638,
1959.
[9] 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.
[10] 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.
[11] 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.
[12] 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.
[13] 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.
[14] 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.
[15] M. C. Shaw, "Metal cutting Principles," Oxford University Press, 2nd
Ed, 2005.
[16] 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.
[17] 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.
[18] V. P. Astakhov, "Tribology of Metal Cutting," London: Elsevier, 2006.
[19] 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.
[20] E. Usui, and H. Takeyama, "A Photoelastic Analysis of Machining
Stress", Trans ASME, J. Eng. Industry, pp. 303-308, 1960.
[21] 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.
[22] 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.
[23] G. Dieter, "Mechanical metallurgy," New York, McGraw-Hill, 1976.
[24] 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.
[25] 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.
[26] 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.
[27] 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.
[28] 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.
[29] R. N. Arnold, "The Mechanism of Tool Vibration in Cutting of Steel,"
Proc. Inst. Mech. Engrs., vol. 27, pp. 261-276, 1946.
[30] 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.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:51821", author = "Samy E. Oraby and Ayman M. Alaskari", title = "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.", keywords = "Mathematical modeling, Cutting forces, Frictionforces, Friction coefficient and Chip ratio.", volume = "5", number = "3", pages = "557-11", }
