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Open AccessArticle
Determination of Chip Compression Ratio for the Orthogonal Cutting Process
by
Michael Storchak
Michael Storchak 1,2
1
Institute for Machine Tools, University of Stuttgart, Holzgartenstraße 17, 70174 Stuttgart, Germany
2
Department of Mechanical Engineering, Zhytomyr Polytechnic State University, Chudnivska Str. 103, 10005 Zhytomyr, Ukraine
J. Manuf. Mater. Process. 2024, 8(5), 190; https://doi.org/10.3390/jmmp8050190 (registering DOI)
Submission received: 5 July 2024
/
Revised: 17 August 2024
/
Accepted: 29 August 2024
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Published: 1 September 2024
Abstract
The chip compression ratio is the most important characteristic of various machining processes with chip generation. This characteristic enables the determination of kinetic and other energy loads on the tool and the machined material. This provides an overall evaluation of the machining process and the possibility of its subsequent optimization. This paper presents the results of determining this cutting characteristic by experimental method, analytical calculation, and numerical modeling. For the analytical calculation of the chip compression ratio, an analytical cutting model developed based on the variational principle of the minimum potential energy was used. A finite element model of orthogonal cutting was used for the numerical simulation of the above process characteristic. Experimentally, the chip compression ratio was determined by the ratio of the chip thickness to the cutting depth (undeformed cutting thickness). The chip thickness was determined by direct measurement using chip slices obtained during the cutting process. The Johnson–Cook constitutive equation was used as the machined material model and the Coulomb model was used as the friction model. The generalized parameters’ determination of the constitutive equation was performed through a DOE (Design of Experiment) sensitivity analysis. The variation range of these parameters was chosen based on the analysis of the effect of individual parameters of the constitutive equation on the chip compression ratio value. The largest deviations between the experimental and analytically calculated values of the chip compression ratio did not exceed 21%. At the same time, the largest deviations of simulated values of the indicated cutting characteristic and its experimental values did not exceed 20%. When comparing the experimental values of the chip compression ratio with the corresponding calculated and simulated values, the deviations were within 22%.
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MDPI and ACS Style
Storchak, M.
Determination of Chip Compression Ratio for the Orthogonal Cutting Process. J. Manuf. Mater. Process. 2024, 8, 190.
https://doi.org/10.3390/jmmp8050190
AMA Style
Storchak M.
Determination of Chip Compression Ratio for the Orthogonal Cutting Process. Journal of Manufacturing and Materials Processing. 2024; 8(5):190.
https://doi.org/10.3390/jmmp8050190
Chicago/Turabian Style
Storchak, Michael.
2024. "Determination of Chip Compression Ratio for the Orthogonal Cutting Process" Journal of Manufacturing and Materials Processing 8, no. 5: 190.
https://doi.org/10.3390/jmmp8050190
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