Experimental validation of machining models

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Kumar, Rajesh Suresh
Kumar, Ananda
Moscoso-Kingsley, Wilfredo
Madhavan, Viswanathan

Kumar, Rajesh,Kumar, Ananda. 2017. Experimental validation of machining models--In Proceedings: 13th Annual Symposium on Graduate Research and Scholarly Projects. Wichita, KS: Wichita State University, p.16


Validation of machining models is usually done using experimental conditions that are far from the assumptions of the models. One of the most difficult experimental conditions to replicate is the friction at the chip-tool interface. To solve this issue, orthogonal cutting of 99.94 percent pure lead has been carried out under near perfect sticking friction conditions. This was achieved by cutting with microtome tools, whose rake faces were coated with a well-adherent layer of lead over which the chip slid by internal shear along the chip-tool interface. After cutting at the target depth of cut, it was observed that most of the transferred lead remained on the rake face. It was found that when sticking friction prevailed, as opposed to the typical sliding on a clean tool, the cutting force went up, the thrust force reversed direction, the chip flow was straighter, and the chip thickness increased.

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Presented to the 13th Annual Symposium on Graduate Research and Scholarly Projects (GRASP) held at the Rhatigan Student Center, Wichita State University, April 28, 2017.
Research completed in the Department of Industrial and Manufacturing Engineering, College of Engineering