Numerical analysis of deformation and surface generation in ultraprecision machining

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Approximate solutions from classical plasticity have in the past been used to describe the process of orthogonal machining. Recently, numerical methods using more complex constitutive models have provided more accurate data on the state of deformation near the tool tip and the generated new surface in a conventional machining process. In this study we have used a viscoplastic material model and an efficient finite element approach to examine the process of orthogonal ultraprecision machining. In contrast to previous numerical studies the cutting thickness to tool tip radius ratio is finite, which requires the use of highly refined finite clement meshes ... continued below

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15 p.

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Anderson, C.A.; Stevens, R.R. & Rhorer, R.L. September 1, 1995.

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Description

Approximate solutions from classical plasticity have in the past been used to describe the process of orthogonal machining. Recently, numerical methods using more complex constitutive models have provided more accurate data on the state of deformation near the tool tip and the generated new surface in a conventional machining process. In this study we have used a viscoplastic material model and an efficient finite element approach to examine the process of orthogonal ultraprecision machining. In contrast to previous numerical studies the cutting thickness to tool tip radius ratio is finite, which requires the use of highly refined finite clement meshes to produce accurate solutions. Results are presented showing the effects of tool edge geometry, material constants, the coefficient of friction, and depth of cut. The numerical results are compared with ultraprecision machining experiments on fine grain copper where thrust and cutting forces and the damaged region around the tool tip (whose profile was characterized by atomic force microscopy) were carefully measured as a function of the uncut chip thickness.

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15 p.

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OSTI as DE96000014

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  • 1995 International mechanical engineering congress and exhibition, San Francisco, CA (United States), 12-17 Nov 1995

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  • Other: DE96000014
  • Report No.: LA-UR--95-2844
  • Report No.: CONF-951135--18
  • Grant Number: W-7405-ENG-36
  • Office of Scientific & Technical Information Report Number: 110806
  • Archival Resource Key: ark:/67531/metadc626676

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  • September 1, 1995

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  • June 16, 2015, 7:43 a.m.

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  • Feb. 25, 2016, 10:05 p.m.

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Anderson, C.A.; Stevens, R.R. & Rhorer, R.L. Numerical analysis of deformation and surface generation in ultraprecision machining, article, September 1, 1995; New Mexico. (digital.library.unt.edu/ark:/67531/metadc626676/: accessed September 25, 2018), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.