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Presentation
Role of Forming In Micro‐ And Nano‐Scale Material Removal Mechanisms During Surface Machining of Ductile Materials
AIP Conference Proceedings
  • Abhijit Chandra, Iowa State University
  • Ashraf F. Bastawros, Iowa State University
Document Type
Conference Proceeding
Conference
Materials Processing and Design: Modeling, Simulation and Applications, NUMIFORM 2004
Publication Version
Published Version
Publication Date
6-1-2004
DOI
10.1063/1.1766511
Conference Title
8TH INTERNATIONAL CONFERENCE ON NUMERICAL METHODS IN INDUSTRIAL FORMING PROCESSES
Conference Date
June 13-17, 2004
Geolocation
(39.9611755, -82.99879420000002)
Abstract

The material detachment mechanisms of ductile metal surfaces are studied experimentally during dry grinding operation in a simulated experiment with near single grit contact with the surface. The spectra of the cutting and thrust forces are recorded and analyzed. It is found that the thrust force changes its direction from a compressive to a tensile mode. The ratio between the thrust and cutting force is consistently found to be greater than 1. In the grinding process, the chip is found to be much shorter and thicker than those predicted by traditional continuum cutting theories. From the analysis of chip dimensions and cutting forces, we speculate that the cutting process during a grinding operation comprises of three phases as follows: (i) lifting up of the surface ahead of the abrasive particle, (ii) segmentation through shear instability, and finally (iii) chip tearing from the surface. Accordingly, the heating cycle is much longer with a lower mean temperature, compared to those of macro machining. In addition, the proposed deformation field leads to loss of constraints ahead of the cutting grits, and possibly reducing the thrust to cutting force ratio. This suggests that forming took place prior to material detachment in grinding.

Comments

The following article appeared in AIP Conference Proceedings 712 (2004): 123, and may be found at doi: 10.1063/1.1766511.

Rights
Copyright 2004 American Institute of Physics. This article may be downloaded for personal use only. Any other use requires prior permission of the author and the American Institute of Physics.
Copyright Owner
American Institute of Physics
Language
en
File Format
application/pdf
Citation Information
Abhijit Chandra and Ashraf F. Bastawros. "Role of Forming In Micro‐ And Nano‐Scale Material Removal Mechanisms During Surface Machining of Ductile Materials" Columbus, OhioAIP Conference Proceedings Vol. 712 (2004) p. 123 - 128
Available at: http://works.bepress.com/ashraf-bastawros/25/