PREDICTIVE MODELING AND OPTIMIZATION OF TURNING OPERATIONS WITH COMPLEX GROOVED CUTTING TOOLS FOR CURLED CHIP FORMATION AND CHIP BREAKING

References

• Armarego , E.J.A. , Jawahir , I.S. , Ostafiev , V.A. and Patri K. Venuvinod , “ Modeling of Machining Operations, ” CIRP Working Group Paper , STC-C, Paris , France ( 1996 ).
   Google Scholar
• Armarego , E.J.A. , “ Predictive Modeling of Machining Operations-A Means of Bridging the Gap Between Theory and Practice, ” Keynote Paper. , CSME Forum, Hamilton , ON , Canada ( 1996 ).
   Google Scholar
• Jawahir , I.S. , Balaji , A.K. , Stevenson , R. and van Luttervelt , C.A. , “ Towards Predictive Modeling and Optimization of Machining Operations, ” ASME Keynote Paper, Manuf Science and Engineering , Dallas , TX , USA ( 1997 ) 3 – 12 .
   Google Scholar
• C. A. van Luttervelt , Childs T.H.C. , Jawahir I.S. , Klocke F. and, Venuvinod P.K. , “ Present Situation and Future Trends in Modeling of Machining Operations ,” Annals of the CIRP , 47 ( 1998 ) 587 – 626 .
   Google Scholar
• Venuvinod , P.K. , “ Prediction Augmentation Through reinforcing Interactions amongst Modeling, STC-C Presentation, ” 46th CIRP General Assembly , Tianjin , P.R. China ( 1997 ).
   Google Scholar
• van Luttervelt C.A. , “ The Importance of Suitable Models for Machining Operations to Improve Machine Tool Performance, ” Proc. Int. Seminar on Improving Machine Tools , San Sebastian, Spain ( 1998 ) 545 – 555 .
   Google Scholar
• van Luttervelt C.A. and, Peng J. , “ Symbiosis of Modeling and Sensing to Improve the Accuracy of Workpieces in Small Batch Machining Operations ,” Int. J. Adv. Manuf Tech. , 15 ( 1999 ) 699 – 710 .
   Web of Science ®Google Scholar
• Jawahir , I.S. , Balaji , A.X. , Rouch , K.E. and Baker , J.R. , “ Towards Integration of Hybrid Models for Optimized Machining Performance in Intelligent Manufacturing Systems, ” Int. Manuf Conference in China , Hong Kong ( 2000 ).
   Google Scholar
• Jawahir , I.S. , Balaji , A.K. and Stevenson , R. , (Editors), Proc. Modeling of Machining Operations, CIRP International Workshop , Atlanta , GA , USA ( 1998 ).
   Google Scholar
• Venuvinod , P.K. , “ Computer-Based Literature Database on Modeling of Machining ,” CIRP Working Group on Modeling of Machining Operations , ( 1998 ).
   Google Scholar
• Young , H.T. , Mathew , P. , and Oxley , P.L.B. , “ Allowing for Nose Radius Effects in Predicting the Chip Flow Direction and Cutting Forces in Bar Turning ,” Proc. Inst, Mech. Engrs. , 201 (C3) ( 1987 ) 213 – 226 .
   Web of Science ®Google Scholar
• Wang , J. and Mathew , P. , “ Development of a General Tool Model for Turning Operations based on a Variable Flow Stress Theory ,” Int. J. of Machine Tools & Manuf. , 35 ( 1 ) ( 1995 ) 71 – 90 .
   Web of Science ®Google Scholar
• Arsecularatne , J.A. , Mathew , P. , and Oxley , P.L.B. , “Prediction of Chip Flow Direction and Cutting Forces in Oblique Machining with Nose Radius Tools,” Proc. Inst. Mech. Eng. , Part B, 209 (1995) 305–315.
   Web of Science ®Google Scholar
• Armarego , E.J.A. and Samaranayake , P. , “ Performance Prediction Models for Tuming with Rounded Comer Plane Faced Lathe Tools. 1. Theoretical Development, 11. Verification of Models ,” Machining Science and Technology , 3 ( 2 ) ( 1999 ) 143 – 200 .
   Web of Science ®Google Scholar
• Jawahir , I.S. , “ An Experimental and Theoretical Study of the Effects of Tool Restricted Contact on Chip Breaking, ” Ph.D. Thesis, The University of New South Wales, Australia ( 1986 ).
   Google Scholar
• Arsecularatne , J.A. and Oxley , P.L.B. , “ Prediction of Cutting Forces in Machining with Restricted Contact Tools ,” Machining Science and Technology , 1 ( 1 ) ( 1998 ) 95 – 112 .
   Web of Science ®Google Scholar
• Redetzky , M. , Balaji , A.K. , Jawahir , I.S. , “ Predictive Modeling of Cutting Forces and Chip Flow in Machining with Nose Radius Tools, ” Proc. 2^nd CIRP Int. Workshop on Modeling of Machining Operations , Nantes , France ( 1999 ) 160 – 180 .
   Google Scholar
• Balaji , A.K. , Sreeram , G. , Jawahir , I.S. , Lenz . E. , “ The Effects of Cutting Tool Thermal Conductivity on Tool-Chip Contact Length and Cyclic Chip Formation in Machining with Grooved Tools ,” Annals of the CIRP , 48 ( 1 ) ( 1999 ) 33 – 38 .
   Google Scholar
• Balaji A . K. , Jawahir , I.S. , “ Effects of Cutting Parameters on Chip Side-Curl Mechanisms and Variable Tool-Chip Contact in Turning ,” Proc. ASME. Symp. Machining Sc. & Tech. , MED-v10 ( 1999 ) 311 – 318 .
   Google Scholar
• Nakayama , K. , “ Chip Control in Metal Cutting ,” Bull. Japan. Soc. of Prec. Eng. , 18 ( 2 ) ( 1984 ) 97 – 103 .
   Web of Science ®Google Scholar
• Ghosh , R. , Redetzky , M. , Balaji , A.K. , Jawahir , I.S. , “ The Equivalent Tool face (ET) Approach for Modeling Chip Curl in Machining with Grooved Tools ,” Proc. CSME Forum , ( 1996 ) 702 – 711 .
   Google Scholar
• Fang , N. , I.S. Jawahir , and P.L.B. Oxley , “ A Universal Slip-line Model With Nonunique Solutions for Machining With Curled Chip Formation and a Restricted Contact Tool ,” Int. J. of Mechanical Sciences , ( 2000 ) (Accepted for publication).
   Web of Science ®Google Scholar
• Fang , N. , and I.S. Jawahir , “ Prediction and Validation of Chip Up-curl in Machining Using the Universal Slip-line Model ,” Trans. NAMRC XXV111 , ( 2000 ) 137 – 142 .
   Google Scholar
• Fang , N. , and I. S. Jawahir , “ Analytical Predictions and Experimental Validation of the Universal Slip-line Field for Restricted Contact Machining ,” Paper submitted to the International Journal of Machine Tools and Manufacture , ( 2000 ).
   Web of Science ®Google Scholar
• Fang , N. , and I. S. Jawahir , “ Prediction of Chip Back-flow Angles in Restricted Contact Machining with Grooved Tools Using the Universal Slip-line Model, ” Proc. ASME 2000 International Mechanical and Engineering Congress and Exposition , November 5 – 10 , Orlando , Florida ( 2000 ).
   Google Scholar
• Shi , T. , and S. Ramalingam , “ Modeling Chip Formation with Grooved Tools ,” Int. J. Mech. Sci. , 35 ( 1993 ) 741 – 756 .
   Web of Science ®Google Scholar
• Dewhurst , P. , “ On the Non-uniqueness of the Machining Process ,” Proc. of R. Soc. Lond. , Series A, 360 ( 1978 ) 587 – 610 .
   Google Scholar
• Kudo , H. , “ Some New Slip-line Solutions for Two-dimensional Steady-state Machining ,” Int. J. Mech. Sci. , 7 ( 1965 ) 43 – 52 .
   Google Scholar
• Johnson , W. , “ Some Slip-line Fields for Swaging or Expanding Indenting, Extruding and Machining for Tools with Curved Dies ,” Int. J. of Mech. Sci. , 4 ( 1962 ) 323 – 347 .
   Google Scholar
• Usui , E. , and Hoshi , K. , “Slip-line Fields in Metal Machining Which Involve Centered Fans,” Prodn. Engg. Res. Conf ASME , Pittsburgh ( 1963) 61–71.
   Google Scholar
• Lee , E.H. and Shaffer , B.W. , “ Theory of Plasticity Applied to a Problem of Machining ,” Applied Mechanics , 18 ( 1951 ) 405 – 413 .
   Web of Science ®Google Scholar
• Merchant , M.E. , “ Basic Mechanism of Metal Cutting Process ,” Applied Mechanics , 11 ( 1944 ) A 168 – 175 .
   Google Scholar
• Powell , MJ.D. , “ A Fortran Subroutine for Solving Systems of Non-linear Algebraic Equations, ” in: Rabinowitz, Numerical Methodsfor Nonlinear Algebraic Equations , Gordon and Breach, London ( 1970 ).
   Google Scholar
• Dewhurst , P. , and Collins , I.F. , “ A Matrix Technique Constructing Slip-line Field Solutions to a Class of Plane Strain Plasticity Problems ,” Int. J. for Num. Meth. in Eng. , 7 ( 1973 ) 357 – 378 .
   Google Scholar
• Hill , R. , “ The Mechanics of Machining: A New Approach ,” J. Mech. Phy. Soli. , 3 ( 1954 ) 47 – 53 .
   Web of Science ®Google Scholar
• Hill , R. , “ On the state of stress in a plastic-rigid body at the yield point ,” Phil. Mag. , 42 ( 1951 ) p 868 .
   Google Scholar
• Hill , R. , “ On the Limits Set by Plastic Yielding to the Intensity of Singularities of Stress ,” J. Mech. Phy. Soli. , 2 ( 1954 ) 278 – 285 .
   Web of Science ®Google Scholar
• Jawahir , I.S. , and C.A. van Luttervelt , “ Recent Development in Chip Control Research and Applications ,” Annals of the CIRP , 42 ( 1993 ) 659 – 693 .
   Google Scholar
• Pekelharing , A.J. , “ Why and How does the Chip Curl and Break ,” Annals of the CIRP , 12 ( 1 ) ( 1964 ) 144 – 147 .
   Google Scholar
• Nakayama , K. , “ Origins of Side Curl of Chip in Metal Cutting ,” Bulletin JSPE , 6 ( 3 ) ( 1972 ) 99 – 101 .
   Google Scholar
• Bhaktavachalam , B. and Venuvinod , P.K. , “ Side Curl of Chips-Its Importance and Prediction in Metal Cutting, ” 6th All India Machine Tool Design Research Conf. , Bangalore ( 1973 ) 235 – 242 .
   Google Scholar
• Shaw , M.C. , Thurman , A.L. and Ahlgren , H.J. , “ A Plasticity Problem involving Plane-Strain and Plane-Stress Simultaneously: Groove Formation in the Machining of High Temperature Alloys ,” ASME J. of Eng. For Ind. , May ( 1966 ) p 142 .
   Google Scholar
• Nakayama , K. , “ Basic Rules on the Form of Chip in Metal Cutting ,” Annals ofthe CIRP , 27 ( 1 ) ( 1978 ) 17 – 21 .
   Google Scholar
• Nakayama , K. and Arai , M. , “ Comprehensive Chip Form Classification Based on the Cutting Mechanism ,” Annals of the CIRP , 41 ( 1 ) ( 1992 ) 71 – 74 .
   Google Scholar
• van Luttervelt C.A. and Pekelharing , AJ. , “ Chip Formation in Machining Operations on Small Diameters ,” Annals of the CIRP , ( 1976 ) 71 – 76 .
   Google Scholar
• Kluft , W. , Konig , W. , van Luttervelt , c.A. , Nakayama , K. , and Pekelharing , AJ. , “ Present Knowledge of Chip Control ,” keynote Paper, Annals of the CIRP , 28 ( 2 ) ( 1979 ) 441 – 455 .
   Google Scholar
• Ghosh , R. , Dillon , O.W. and Jawahir , I.S. , “ An Investigation of 3D Curled Chip in Machining-Part I: A Mechanics-Based Analytical Model ,” J. Machining Sci. & Tech. , 2 ( 1 ) ( 1998 ) 91 – 116 .
   Web of Science ®Google Scholar
• Nakayama , K. , “ A Study on Chip Breaker ,” Bull. JSME , ( 1962 ) 142 – 150 .
   Google Scholar
• Balaji , A.K. , “ An Experimental and Theoretical Study of Variable Tool-Chip Interfacial Friction and Cyclic Chip Formation in Machining with Flat-Faced and Grooved Tools, ” Ph.D. Thesis, University of Kentucky, USA ( 2000 ).
   Google Scholar
• Jawahir , I.S. , O.W. Dillon , A.K. Balaji , M. Redetzky , and N. Fang , “Predictive Modeling of Machining Performance in Turning Operations,” J. Machining Science and Technology , 2 (1998) 253–276.
   Web of Science ®Google Scholar
• Fang , X.D. , Jawahir , I.S. , “ An Analytical Model for Cyclic Chip Formation in 2D Machining with Chip Breaking ,” Annals of the CIRP , 45 /1 ( 1996 ) 53 – 58 .
   Google Scholar
• Jawahir , I.S. , Zhang , J.P. , “ An Analysis of Chip Curl Development, Chip Deformation and Chip Breaking in Orthogonal Machining ,” Trans. NAMRIISME , 23 ( 1995 ) 109 – 114 .
   Google Scholar
• Wang , L. , Saito , K. and Jawahir , I. S. , “ Infrared Temperature Measurement of Curled Chip Formation in Metal Machining ,” Trans. NAMRI , XX1V , ( 1996 ) 87 – 92 .
   Google Scholar
• Wang , L. , “ An Investigation of Temperature Effects on Curled Chip Formation in Metal Machining, ” Ph.D. Thesis, University of Kentucky, USA ( 1996 ).
   Google Scholar
• Jawahir , I.S. , “ The Tool Restricted Contact Effect as a Major Influencing Factor in Chip Breaking: An Experimental Analysis ,” Annals ofthe CIRP , 37 ( 1 ) ( 1998 ) 121 – 126 .
   Google Scholar
• Jawahir , I.S. , “ On the Controllability of Chip Breaking Cycles and Modes of Chip Breaking in Metal Machining ,” Annals of the CIRP , 39 ( 1 ) ( 1990 ) 47 – 51 .
   Google Scholar
• Jawahir , I.S. and Fei , J. , “ A Comprehensive Evaluation of Tool Inserts for Chip Control Using Fuzzy Modeling of Machinability Parameters ,” Trans. NAMRI , XX1 , ( 1993 ) 205 – 213 .
   Google Scholar
• Lin , M. , Ghosh , R. and Jawahir , I.S. , “ An Intelligent Technique for Predictive Assessment of Chip Breakability in Turning Operations for Use in CAPP Systems ,” Proc. IPMM'97, Australisia-Pacific Forum on Intelligent Processing & Manuf of Materials , 2 ( 1997 ) 1311 – 1320 .
   Google Scholar
• Da , Z,J. , J.P. Sadler , X.D. Fang , and I.S. Jawahir , “ Optimum Machining Performance in Finish Turning with Complex Grooved Tools ,” Manufacturing Science and Engineering , MED-Vol. 2–1 MH-Vol. 3–1 ASME ( 1995 ) 703 – 714 .
   Google Scholar
• Da , Z,J. , J.P. Sadler , and I.S. Jawahir , “ Predicting Optimum Cutting Conditions for Turning Operations at Varying Tool-Wear States ,” Transactions of NAMRIISME , XXV , ( 1997 ) 75 – 80 .
   Google Scholar
• Da , Z,J. , Sadler , J.P. , and Jawahir , I.S. , “ A New Performance-Based Criterion for Optimum Cutting Conditions and Cutting Tool Selection in Finish Turning ,” Trans. NAMRIISME , XXV1 , ( 1998 ) 129 – 134 .
   Google Scholar
• Fang , X.D. and Jawahir , I.S. , “ The Effects of Progressive Tool-Wear and Tool Restricted Contact on Chip Breakability in Machining ,” Wear , 160 ( 1993 ) 243 – 252 .
   Web of Science ®Google Scholar