Abstract
The purpose of this study is to explain the experimentally observed variations in cutting parameters during the machining of single-crystal materials. Fundamental relationships between crystal plasticity and machining are developed. The workpiece anisotropy stem from crystallographic differences are explained with a rate-insensitive Taylor plasticity model. A brief discussion of the applicability of Schmid-based models to machining processes is also presented. The periodic variations with changing crystal orientations observed in experimental studies are explained with the results of the proposed model for machining. The friction between the rake face of the tool and the material is introduced to the existing model. The applicability of concepts like Texture Softening Factor and Effective Taylor Factor in previous works are discussed. The specific energy of cutting is related to Taylor factor for better understanding of crystallographic effects.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Shaw MC, Finnie I (1955) Shear stress in metal cutting. Trans ASME, pp 115–125
Van Luttervelt CA, Childs THC, Jawahir IS, Klocke F, Venuvinod PK (1998) Present situation and future trends in modeling of machining operations. CIRP 47:587–636
Manjunathaiah J, Endres WJ (2000) A new model and analysis of orthogonal machining with an edge-radiused tool. Trans ASME 122:384–390
Taylor GI (1938) Plastic strain in metals. Inst Metals 62:307–325
Bishop JFW, Hill R (1951) A theory of plastic distortion of a polycrystalline aggregate under combined stresses. Phila Mag 42:1298–1307
Reid CN (1973) Deformation geometry of materials, 1st edn. Pergamon Press, Oxford
Kocks UF, Tome CN, Wenk HR (1998) Texture and anisotropy. Cambridge University Press, Cambridge
Cohen P, Black JT (1984) Strain, strain rate and shear velocity measurements in metal cutting. High Energy Rate Fabrication. ASME pp 271–278
Black JT (1979) Flow stress model in metal cutting. J Eng Ind 101:403–415
Koenig W, Spenrath N (1991) Influence of crystallographic structure of the substrate material on surface quality and cutting forces in micromachining. Proceedings of the International Precision Engineering Seminar, pp 141–151
Williams JA, Horne JG (1982) Crystallographic effects in metal cutting. J Mater Sci 17:2618–2624
Sato M, Kato Y, Tsutiya K, Aoki S (1980) Effects of crystal orientation on the cutting mechanism of aluminum single crystal. Bull JSME 24(215):1864–1870
Ueda K, Iwata K, Nakajama K (1980) Chip formation mechanism in single-crystal cutting β-Brass. Ann CIRP - Manufacturing Technology 29(1):41–46
Yan J, Syoji K, Tamaki J (2004) Crystallographic effects in micro/nanomachining of single-crystal calcium fluoride. J Vac Sci Technol B22(1):46–51
Lee WB (1990) Prediction of microcutting force variation in ultra-precision machining. Precis Eng 12(1):25–28
Zhou M, Ngoi BK (2001) Effect of tool and workpiece anisotropy on microcutting processes. IMechE J Eng Manuf 215:13–19
Lee WB, Cheung CF, To S (2002) A microplasticity analysis of micro-cutting force variation in ultra-precision diamond turning. Trans ASME 124:170–177
Lee WB, Chan KC (1990) Symmetry requirement in shear band formation. Scr Mater 24:997–1002
Lee WB, Zhou M (1993) A theoretical analysis of the effect of crystallographic orientation on chip formation in micromachining. Int J Mach Tools Manuf 33(3):439–447
Lee WB, To S, Sze YK, Cheung CF (2003) Effect of material anisotropy on shear angle prediction in metal cutting - a mesoplasticity approach. Int J Mech Sci 45:1739–1749
Lee WB, To S, Cheung CF (2000) Effect of crystallographic orientation in diamond turning of copper single crystals. Scr Mater 42:937–945
Lee WB, Cheung CF (2001) A dynamic surface topography model for the prediction of nano-surface generation in ultra-precision machining. Mech Sci 43:961–991
Lee WB, To S, Cheung CF (2003) Friction-induced fluctuation of cutting forces in the diamond turning of aluminum single crystals. IMechE J Eng Manuf 217:615–631
Ohmori G, Takada S (1982) Primary factors effecting accuracy in ultra-precision machining by diamond tools. Bull Jpn Soc Precis Eng 16(1):3–7
Moriwaki T, Okuda K (1989) Machinability of copper in ultra-precision micro diamond cutting. Ann CIRP 38(1):115–118
Arcona C, Dow TA (1998) An empirical tool force model for precision machining. Trans ASME 120:700–707
Rubenstein C, Lau WS, Venuvinod PK (1985) Flow of workpiece materials in the vicinity of the cutting edge. Int J Mach Tool Des Res 25:91–97
Lucca DA, Seo YW (1994) A sliding indentation model of the tool–workpiece interface in ultra-precision machining. Tribology Symposium ASME, pp 17–22
Liang Y, Moronuki N, Furukawa Y (1994) Calculations of the effect of material anisotropy on microcutting process. Precis Eng 16:132–138
Iwata K, Osakada K, Terasaka Y (1984) Process modeling of orthogonal cutting by the rigid-plastic finite element method. Trans ASME 106:132–138
Wince JN (2002) Modeling chip formation in orthogonal metal cutting using finite element methods. Master’s Thesis, Mississippi State University, Mech Eng. Dept
Ikawa N, Shimada S, Tanaka H (1992) Minimum thickness of cut in micromachining. Nanotechnology 3:6–9
Komanduri R, Chandrasekaran N, Raff LM (1999) Orientation effects in nanometric cutting of single-crystal materials an MD simulation approach. Ann CIRP, pp 67–72
Author information
Authors and Affiliations
Corresponding author
Additional information
This work was partially completed with Prof. Burak Ozdoganlar, Carnegie Mellon University, Mechanical Eng. Dept.
Rights and permissions
Open Access This is an open access article distributed under the terms of the Creative Commons Attribution Noncommercial License ( https://creativecommons.org/licenses/by-nc/2.0 ), which permits any noncommercial use, distribution, and reproduction in any medium, provided the original author(s) and source are credited.
About this article
Cite this article
Demir, E. A Taylor-based plasticity model for orthogonal machining of single-crystal FCC materials including frictional effects. Int J Adv Manuf Technol 40, 847–856 (2009). https://doi.org/10.1007/s00170-008-1409-5
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-008-1409-5