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Tables of Contents for Metal Cutting Mechanics
Chapter/Section Title
Page #
Page Count
Introduction
1
10
General
1
1
Reasons for studying metal cutting
2
1
History of metal cutting
3
3
Basic problems requiring solution
6
5
References
8
3
System approach
11
62
Observation part of existing studies on chip formation
12
3
System and assemblage
15
11
Mathematical definition of system
15
5
Mathematical definition of an assemblage
20
1
The relation between a system and an assemblage
21
5
Cutting system
26
47
First step: time dependence of parameters of cutting system and their dynamic interactions
26
1
First stage: observational part
26
7
Second stage: experimental verification
33
6
Third stage: quantitative analysis of the bending stress
39
5
Definition of the metal cutting process
44
1
Difficulties due to high ductility of workpiece material
45
2
Model of chip formation when seizure occurs at tool-chip interface
47
4
Generalized model of chip formation and structure classification
51
4
Second step: controllability of the cutting system
55
6
Principle of control of the cutting system
61
8
References
69
4
Parallel-sided deformation zone theory
73
54
The role of engineering plasticity in metal cutting studies
73
6
Velocity diagram: what seems to be the problem?
79
2
Role of the velocity diagram in the theory of metal cutting
81
1
The discontinuity of the tangential velocity
82
6
Real velocity diagram in metal cutting
88
6
Velocity diagram at the second stage
88
6
Velocity diagram at the third stage
94
1
Real virtual work equation
94
1
Analysis of plastic deformation in metal cutting
95
22
Chip compression ratio and strain --- what is a real measure of plastic deformation in metal cutting?
95
3
Infinitesimal strain
98
4
The rotational element
102
3
Infinitesimal strain of a line element
105
1
Strain compatibility equation
106
2
Finite displacement of a point in a continuous body
108
1
Finite strain
109
2
Principal strains and strain invariants
111
2
Increments in the strain components
113
1
Strain in metal cutting
114
3
Strain rate in metal cutting
117
10
Reported strain rates
117
2
Critical analysis of the reported strain rates
119
2
Strain rate tensor
121
2
References
123
4
Work material considerations
127
56
What has to be predicted according to existing theories?
128
1
Review of attempts made to predict shear flow stress
129
3
The first approach
130
1
The second approach
131
1
The third approach
132
1
What has to be predicted in reality?
132
2
Experimental verification
134
7
Incremental compression
134
2
Metal cutting
136
1
Influence of high temperatures
137
4
The cause of significant discrepancies in reported results
141
2
Nature of plastic deformation of polycrystalline materials
143
13
Fracture and its correlation with deformation
143
2
Plasticity and stress relaxation
145
2
Defect population in metals
147
3
Influence of the state of stress
150
4
Generalizations
154
2
Fracture of ductile polycrystallines
156
1
Mechanism of fracture in metal cutting
156
11
Possible regions of fracture
157
1
Experimental evidence
158
5
Type of fracture
163
4
Fracture strain determination
167
16
Existent criteria of ductile fracture
169
2
Basic starting concepts for the analysis of ductile fracture
171
3
Relationship between strain at fracture of a material and parameters of current plastic deformation
174
4
References
178
5
Finite element simulation
183
30
General
183
1
FEM in metal cutting
183
1
Aims and layout
184
1
Computational details of simulation
184
5
Program structure
185
2
Workpiece and tool materials modeling
187
2
Applications of FEM
189
2
Results and discussion
191
13
Modeling of the deformation zone
192
5
Modeling of the tool/chip interface
197
1
Known results
197
1
Simulation of stress distribution at tool/chip interface
198
1
Shear stress distribution
198
1
Normal stress distribution
199
3
Contact processes at the tool/chip interface
202
2
Comparison with machining experiments
204
9
References
210
3
Methodology of experimental studies in metal cutting
213
58
Similarity methods in metal cutting
213
32
General
213
2
Basics of similarity
215
3
Applications in metal cutting studies
218
1
Optimum cutting temperature---Makarow's law
218
9
Similarity numbers
227
2
Use of similarity numbers in metal cutting
229
1
Energy balance
229
5
Optimum cutting speed and machinability
234
4
Quality of the machined surface and tool wear
238
7
Temperature measurements in metal cutting
245
10
Conventional thermocouples
245
4
Tool-work (natural) thermocouple
249
4
Semi-artificial and running thermocouples
253
2
Cutting force measurements
255
16
General
255
2
Procedure used in the current study
257
10
References
267
4
Appendix. Cutting tool geometry
271
18
A.1 Tool-in-hand system
271
5
A.1.1 Planes
271
1
A.1.2 Angles
272
4
A.2 Tool-in-machine system (setting system)
276
3
A.3 Tool-in-use system
279
4
A.4 Determination of the uncut chip cross-section for non-free and non-orthogonal cutting conditions
283
6
References
287
2
Index
289