An Investigation of the High Speed Machining Process Using a Variable Flow Stress Machining Theory

Abstract

This article investigates the application of the Oxley modeling approach to high speed machining (HSM) process for gaining a fundamental understanding and performance prediction of this process which is gaining increased popularity due to its many economic and technological advantages such as faster metal removal rates, efficient use of machine tools and, improved surface finish and lower cutting forces. Oxley's theory has so far mainly been applied for making machining predictions for plain carbon steels in the conventional speed range. In the present work, this theory has been applied for two plain carbon steels and a low alloy steel under HSM conditions. The predicted cutting forces, chip thicknesses, and secondary deformation zone thicknesses are then compared with the experimental results obtained under identical conditions. Good agreement has been shown between measured and predicted results. In addition, the possibility of applying the theory to predict the tool life and tool deformation conditions is also explored. An ability to predict these process parameters is of paramount importance since catastrophic tool failure under HSM conditions can be extremely costly and dangerous.

Keywords:

• High speed machining
• Variable flow stress
• Machining theory
• Steel work materials

Acknowledgments

The authors wish to thank Mr G. Schubert for his help during the experimental work and the Australian Research Council and The University of New South Wales (URSP Fund 2001) for financial support.