Prediction of Forces, Stresses, Temperatures and Tool Wear in Metal Cutting

In the present work, an analytical computer program (OXCUT) is developed to predict cutting variables. The temperatures and forces, predicted by OXCUT, have been found to be in reasonable agreement with published experimental results.Moreover, flow stress data, at the high strains, strain rates and temperatures, encountered in metal cutting operations, has been determined using OXCUT in conjunction with 2-D orthogonal slot milling experiments and multidimensional minimization using the Downhill Simplex Method. The OXCUT and FEM predicted cutting variables, using the obtained flow stress data, have been found to be in reasonable agreement with the measured results. The obtained flow stress data has been used, in conjunction with the FEM code DEFORM, to study the influence of edge preparation of cutting tools on tool stresses, cutting temperatures and forces. It has been concluded that the hone-radius edge with hone radius of 0.1 mm may have the least probability of chipping and the chamfered edge (20°X0.1 mm) may have the minimum flank and crater wears for the conditions used in the present study.Furthermore, OXCUT and published measured crater and flank wear results have been used to estimate the empirical parameters of a characteristic wear equation to predict crater and flank wear of HSS, Carbide P20 and Carboloy 370 inserts when cutting low carbon steels. The estimated parameters of the characteristic wear equation have been used, in conjunction with OXCUT, to approximate the flank and crater wear rate distributions along the twist drill lip when drilling low carbon steels. A parametric study has been conducted to investigate the influence of spindle speed, feed, workpiece material, and drill helix angle on the crater and flank wear rates along the lip of twist drills made of Carboloy 370 and Carbide P20. The important observations of this parametric study are: (1) increasing the drill helix angle reduces crater and flank wear, (2) Carboloy 370 is more resistant to drill crater wear than Carbide P20 at low feeds and the opposite is true at high feeds, and (3) Carboloy 370 is less resistant to drill flank wear than Carbide P20. Advisors/Committee Members: Altan, Taylan.