• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.2
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• pp.292-301
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• 1994

The resultant cutting force during machining with a worn tool is viewed as a decomposition of the cutting force into a cutting force component related to chip removal from the workpiece and into a component dependent on the contact force between the tool flank's wear land and the workpiece. The shear line method, in which the cutting force is considered proportional to the length of the shear line, is used to calculate the cutting force component for the removal of the chip, while the elastic effect of the workmaterial on the tool is taken into consideration to analyze the effect of tool flank wear. The predicted resultant cutting force, expressed as the sum of both components, is compared to experimental data obtained during wave-on-wave cutting.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2003.04a
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• pp.223-228
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• 2003

In end milling processes, characterized by use of rotating tools, the underformed chip thickness varies periodically with the phase change of tool. In current study, as a new approach to analyse shear behaviors In the shear plane and chip-tool friction behavior chip-tool contact region during an end milling process. In this approach, an up-end milling process is transformed into an equivalent oblique cutting process. Experimental investigations for two sets of cutting tests i.e.. up-end milling and the equivalent oblique cutting test were performed to verify the presented model.

• Transactions of Materials Processing
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• v.12 no.4
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• pp.358-363
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• 2003

Adiabatic shear bands have been observed in the serrated chip during high strain rate metal cutting process of medium carbon steel and titanium alloy The recent microscopic observations have shown that dynamic recrystallization occurs in the narrow adiabatic shear bands. However the conventional flow stress models such as the Zerilli-Armstrong model and the Johnson-Cook model, in general, do not predict the occurrence of dynamic recrystallization (DRX) in the shear bands and the thermal softening effects accompanied by DRX. In the present study, a strain hardening and thermal softening model is proposed to predict the adiabatic shear localized chip formation. The finite element analysis (FEA) with this proposed flow stress model shows that the temperature of the shear band during cutting process rises above 0.5Τ$_{m}$. The simulation shows that temperature rises to initiate dynamic recrystallization, dynamic recrystallization lowers the flow stress, and that adiabatic shear localized band and the serrated chip are formed. FEA is also used to predict and compare chip formations of two flow stress models in orthogonal metal cutting with AISI 1045. The predictions of the FEA agreed well with the experimental measurements.s.

• Smart Structures and Systems
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• v.24 no.3
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• pp.345-360
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• 2019

The shear keys are set in a seismic isolation system to resist the long-term service loadings, and are cut off to isolate the earthquakes. This paper investigated the influence of shear keys on the seismic performance of a vertical spring-viscous damper-concave Coulomb friction isolation system by an incremental dynamic analysis (IDA) and a performance-based assessment. Results show that the cutting off process of shear keys should be simulated in a numerical analysis to accurately predict the seismic responses of isolation system. Ignoring the cutting off process of shear keys usually leads to untrue seismic responses in a numerical analysis, and many of them are unsafe for the design of isolated structure. And those errors will be increased by increasing the cutting off force of shear keys and decreasing the spring constant of shear keys, especially under a feeble earthquake. The viscous damping action postpones the cutting off time of shear keys during earthquakes, and reduces the seismic isolation efficiency. However, this point can be improved by increasing the spring constant of shear keys.

• Journal of the Korean Society for Precision Engineering
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• v.1 no.2
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• pp.24-32
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• 1984

The object of the study is to discuss the effect of magic ink as a surface active substance on the mechanism of chip formation in oblique cutting. The Rehbinder effect has been known as a phenomenon that the mechanical strength reduces when the metal is coated with some surface active substances. In order to interpret these surface effects defined by Rehbinder, the influence on the shear strength of shear plane by coating surface active substances, cutting force by the depth of cut, surface roughness and hardness ratio were observed. The results are as follows: 1. By coating the magic ink on free surface of the forming chip, the effective shear angle increases, and the cuttinbg force and the deformed chip thickness decreases. 2. With the large inclination angle the effective shear angle increases, and the specific cutting force and the friction angle decrease. 3. Cutting of the coated surface improves the surface roughness and the hardness ratio drops, which means another Rehbinder effect.

• Journal of Mechanical Science and Technology
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• v.18 no.5
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• pp.770-779
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• 2004

This paper describes the micro cutting of wear resistant tungsten carbides using PCD (Poly-Crystalline Diamond) cutting tools in performance with SEM (Scanning Electron Microscope) direct observation method. Turning experiments were also carried out on this alloy (V50) using a PCD cutting tool. One of the purposes of this study is to describe clearly the cutting mechanism of tungsten carbides and the behavior of WC particles in the deformation zone in orthogonal micro cutting. Other purposes are to achieve a systematic understanding of machining characteristics and the effects of machining parameters on cutting force, machined surface and tool wear rates by the outer turning of this alloy carried out using the PCD cutting tool during these various cutting conditions. A summary of the results are as follows: (1) From the SEM direct observation in cutting the tungsten carbide, WC particles are broken and come into contact with the tool edge directly. This causes tool wear in which portions scrape the tool in a strong manner. (2) There are two chip formation types. One is where the shear angle is comparatively small and the crack of the shear plane becomes wide. The other is a type where the shear angle is above 45 degrees and the crack of the shear plane does not widen. These differences are caused by the stress condition which gives rise to the friction at the shear plane. (3) The thrust cutting forces tend to increase more rapidly than the principal forces, as the depth of cut and the cutting speed are increased preferably in the orthogonal micro cutting. (4) The tool wear on the flank face was larger than that on the rake face in the orthogonal micro cutting. (5) Three components of cutting force in the conventional turning experiments were different in balance from ordinary cutting such as the cutting of steel or cast iron. Those expressed a large value of thrust force, principal force, and feed force. (6) From the viewpoint of high efficient cutting found within this research, a proper cutting speed was 15 m/min and a proper feed rate was 0.1 mm/rev. In this case, it was found that the tool life of a PCD tool was limited to a distance of approximately 230 m. (7) When the depth of cut was 0.1 mm, there was no influence of the feed rate on the feed force. The feed force tended to decrease, as the cutting distance was long, because the tool was worn and the tool edge retreated. (8) The main tool wear of a PCD tool in this research was due to the flank wear within the maximum value of $V_{max}$ being about 260 $\mu\textrm{m}$.

• Journal of the Korean Society for Precision Engineering
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• v.4 no.3
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• pp.44-51
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• 1987

In metal cutting various types of chips are produced in consequence of cutting conditions. Flow-type chips have been studied in most cases because they are easier to be analyzed, but the actual surfaces of chips are not smooth, but crushed. This paper deals with saw-toothed chips, special types of flow-type chips, which have deep concaves and high convexes and sharp angles on the free surface. I tried to establish the theory of saw-toothed chip mechanism through experimental observation, that is, the mathmatical model of the cutting energy and cutting mechanism through the geometrical observation of the chips by using a microscope. The results obtained are as follows: 1. The mechanism of saw-toothed chips is diffenent from that of general flow-chips. 2. In the case of saw-toothed chips, the shear angle must be measured by the hypotenuse angle and the rake angle, and the shear angle is more affected by the rake angle than by the hypotenbuse angle. 3. The friction angle is represented by .beta. = . pi. /4+ .alpha./ sub n/- .phi. which is different from Merchant's equation. 4. The pitch and the slip are greatly influenced by depth of cut, but the influence of the rake angle on it is small. 5. The normal stress and the shear stress on the shear plane decrease with the increase of the cutting depth, and they are almost independent on the variation of a rake angle. 6. The unit friction energy on the tool face, the unit shear energy on the shear plane, and the total cutting energy per unit volume decrease with the increase of rake angle and cutting depth.

• Transactions of the Korean Society of Mechanical Engineers
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• v.12 no.2
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• pp.252-261
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• 1988

Through the careful interpretation of the results of the cutting tests carried out in this study, it is found that under the cutting conditions when the internal shear of the chips take place the cutting can be treated essentially as a steady state problem. A new shear angle equation has been developed employing the conditions of force and moment equilibrium about the tool edge and the stress distribution model suggested by Zorev.The equation contains the chip-tool contact length C and stress distribution index n as important parameters.

• Journal of the Korean Society for Precision Engineering
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• v.6 no.2
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• pp.40-46
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• 1989

Recently, the researches on cutting the new material have been done for development of aerospace industrial engineering. Especially, titanium ally is well known as heat resisting, antiwear, anticorrosion and difficult-to-machine materials. Many studies on the analysis of shear angle have been done for improving productivity in cutting these materials. In case of titanium alloy, the saw-toothed type of chip which has wave surface of a triangular form, an eccentric from of a continuous type of chip that is produced in the cutting process, was checked. Nakayama supposed that a maximum shear strewss plane and the shear crack in the free surface made an angle of $45^{\circ}$ .deg. , but it's usually much larger than that. In this paper, the author analyzed the shear conditions of the cutting process in the quick-stopping device with the help SEM-photographs, and measured the hypotenuse angle directly in the photographs of the chips. In conclusion, the author tried to find the shear angle in the cutting process with the saw-toothed chip and compared it with the shear angles which can be calculated from the theories established by others. The results obtained are as follows. 1. In case of the saw-toothed chips, the equivalent cutting ratio can be calculated by using the chip thickness to two-thirds of ramp height. 2. The theory of Ernst-Merchant is not applicable to the titanium and its alloys which does not fractured in accordance with the theory of maximum shear stress. 3. When we cut the titanium alloys which produced the saw-toothed chips, the shear angle can be found with the theories of Rowe-Spick, P.K. Wright and the measurement of hypotenuse angle.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.427-733
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• 2003

Adiabatic shear bands have been observed in the serrated chip during high strain rate metal cutting process of medium carbon steel and titanium alloy. The recent microscopic observations have shown that dynamic recrystallization occurs in the narrow adiabatic shear bands. However the conventional flow stress models such as the Zerilli-Armstrong model and the Johnson-Cook model, in general, do not predict the occurrence of dynamic recrystallization (DRX) in the shear bands and the thermal softening effects accompanied by DRX. In the present study, a strain hardening and thermal softening model is proposed to predict the adiabatic shear localized chip formation. The finite element analysis (FEA) with this proposed flow stress model shows that the temperature of the shear band during cutting process rises above 0.5T$\sub$m/. The simulation shows that temperature rises to initiate dynamic recrystallization, dynamic recrystallization lowers the flow stress, and that adiabatic shear localized band and the serrated chip are formed. FEA is also used to predict and compare chip formations of two flow stress models in orthogonal metal cutting with AISI 1045. The predictions of the FEA agreed well with the experimental measurements.