High speed machining (HSM) produces parts with substantially higher fatigue strength; increased subsurface micro-hardness and plastic deformation, mostly due to the ploughing of the cutting tool associated with residual stresses, and can have far more superior surface properties than surfaces generated by grinding and polishing. In this paper, a dynamics explicit Arbitrary Lagrangian Eulerian (...

In this study, an analytical slip-line approach is utilized to investigate the friction factor at the tool-chip interface and dead metal zone phenomenon in orthogonal cutting with chamfered tools. Analytical thermal modeling of chamfered tools is also formulated and integrated into the model. Orthogonal cutting of AISI 4340 steel is performed. Measured forces are utilized in identifying the fri...

In this experimental study, three TiB2/Al metal matrix composites (MMCs) with 40 μm in mean size were produced using a melt stirring squeeze casting route. Test was carried out to find the parameters influencing surface roughness (Ra) and material removal rate (MRR) on machining the TiB2 reinforced Al-6063 composite materials. The orthogonal array, the signal-to-noise ratio, and analysis of var...

Consider the feasibility problem in higher-dimensional orthogonal packing. Given a set I of d-dimensional rectangles, we need to decide whether a feasible packing in a d-dimensional rectangular container is possible. No item rotation is allowed and item edges are parallel to the coordinate axes. Typically, solution methods employ some bounds to facilitate the decision. Various bounds are known,...

Quality and productivity are two important aspects for manufacturing industries. Modeling and optimization is the best technique applied to find the best manufacturing conditions. This technique has been applied to investigate the optimized design of the cutting process in end milling for Al 6061 alloy in order to provide better surface finish as well as high Material Removal Rate (MRR). The cu...

The dynamics of the cutting process are investigated. Using the increase of cutting depth as a control parameter, two diierent cutting regimes are observed. In the rst regime, which is observed at small cutting depths, complex, high-dimensional dynamics occur. In the second cutting regime, observed for deeper cuts, low dimensional dynamics are typical. The second cutting regime is usually ident...

The present work is concentrated with the dry turning of AISI 304 Austenitic Stainless Steel (ASS). This paper presents the influence of cutting parameters like cutting speed, feed rate and depth of cut on the surface roughness of austenitic stainless steel during dry turning. A plan of experiments based on Taguchi’s technique has been used to acquire the data. An orthogonal array, the signal t...

A slip-line field model for orthogonal cutting with step-type chip breaker assuming adhesion friction at chip/tool interface is developed using Kudo’s basic slip-line field. An alternative method is suggested for estimation of breaking strain in the chip. The model proposed predicts that with decrease in distance of chip breaker from the cutting edge of the tool, the breaking strain and shear s...