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Numerical and experimental investigation of the shear angle in high-speed cutting of Al6061-T6

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Abstract

The shear angle is one of the important factors in cutting deformation and the shear angle theory reveals the relationship between the shear behavior in the primary zone and the tool-chip friction behavior in the secondary zone. In order to deepen the understanding of shear angle theory, the study investigated the shear angle variation in aluminum alloy Al6061-T6 and compared the three conventional shear angle models, Merchant, Lee and Shaffer, and Hucks. To obtain the shear angle more conveniently, a simple approach utilizing the connection between the shear angle and chip thickness was proposed. Orthogonal cutting experiments were conducted on aluminum alloy Al6061-T6. A new cutting simulation model for shear angle and chip thickness of Al6061 with errors below 15% and 10% respectively was proposed in the study. What’s more, it was found that the three shear angle models have their applicable ranges in cutting speed for the aluminum alloy. It is mainly because the internal friction coefficient of workpiece material decreased as cutting speed rose.

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Acknowledgements

We thank Melissa Gibbons, PhD, from Liwen Bianji, Edanz Editing China (www.liwenbianji.cn/ac), for editing the English text of a draft of this manuscript.

Funding

This work was supported by the National Natural Science Foundation of China (51875045).

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Authors and Affiliations

  1. School of Technology, Beijing Forestry University, Beijing, 100083, China

    Mohan Hao & Daochun Xu

  2. Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

    Pingfa Feng

Authors
  1. Mohan Hao
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  2. Daochun Xu
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  3. Pingfa Feng
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Corresponding author

Correspondence to Daochun Xu.

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Hao, M., Xu, D. & Feng, P. Numerical and experimental investigation of the shear angle in high-speed cutting of Al6061-T6. Int J Adv Manuf Technol 100, 3037–3044 (2019). https://doi.org/10.1007/s00170-018-2842-8

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  • DOI: https://doi.org/10.1007/s00170-018-2842-8

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