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Effects of Controlled Modulation on Interface Tribology and Deformation in Machining

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Abstract

The effects of superimposed, low-frequency modulation on contact conditions at the tool–chip interface and mechanics of machining are analyzed. It is shown that modulation can disrupt the severity of the tool–chip contact, enabling enhanced lubrication of this contact; and discretize chip formation to small dimensions with controlled size and shape. The deformation strain in the chip is also reduced, suggesting a 40% reduction in energy of machining due to the modulation. Conditions of frequency and amplitude for achieving these effects are presented and confirmed using a compact modulation device that can be retro-fitted onto conventional machine platforms. Implications for enhancing efficiency of industrial machining processes are briefly discussed.

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Acknowledgments

This work was supported in part by the National Science Foundation STTR Award 0822879, a National Science Foundation grant CMMI 0654250, the State of Indiana 21st Century Fund and M4 Sciences. We would like to thank Dr. Michael Sevier (University of California, Santa Barbara, CA) for sharing with us some of the results of a finite element analysis.

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Authors and Affiliations

  1. Center for Materials Processing and Tribology, School of Industrial Engineering, Purdue University, West Lafayette, IN, 47907-2023, USA

    J. B. Mann, C. Saldana, W. Moscoso, W. D. Compton & S. Chandrasekar

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  1. J. B. Mann
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  2. C. Saldana
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  3. W. Moscoso
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  4. W. D. Compton
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  5. S. Chandrasekar
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Correspondence to S. Chandrasekar.

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Mann, J.B., Saldana, C., Moscoso, W. et al. Effects of Controlled Modulation on Interface Tribology and Deformation in Machining. Tribol Lett 35, 221–227 (2009). https://doi.org/10.1007/s11249-009-9451-5

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  • DOI: https://doi.org/10.1007/s11249-009-9451-5

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