Title: Computational analysis of the intimate contact between an inclined wedge and low carbon steel during metal cutting

Authors: M.J. Jackson, M.D. Whitfield, J.S. Morrell, J. Paulo Davim

Addresses: Centre for Advanced Manufacturing, MET, College of Technology, Purdue University, 401 North Grant Street, West Lafayette, Indiana, IN 47907-2021, USA. ' Centre for Advanced Manufacturing, MET, College of Technology, Purdue University, 401 North Grant Street, West Lafayette, Indiana, IN 47907-2021, USA. ' Centre for Advanced Manufacturing, MET, College of Technology, Purdue University, 401 North Grant Street, West Lafayette, Indiana, IN 47907-2021, USA. ' Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal

Abstract: The initial stages of intimate contact between an inclined wedge and low carbon steel creates significant opportunities for manufacturers of machined products to understand how dry machining and minimum quantity lubrication affect the economics of manufacturing, especially when one considers how important frictional interactions between chip and tool are on the final structure of the workpiece materials in terms of structural phase transformations. The present work not only compares various computational approaches to the solution of shear plane and tool face temperatures, but also explains why there is a large discrepancy when calculating temperature generated during machining when using Loewen and Shaw|s method for calculating shear plane and tool face temperatures.

Keywords: machinability; cutting tools; computational analysis; inclined wedge; low carbon steel; metal cutting; intimate contact; manufacturing economics; dry machining; minimum quantity lubrication; MQL; shear plane temperature; tool face temperature.

DOI: 10.1504/IJMPT.2010.029456

International Journal of Materials and Product Technology, 2010 Vol.37 No.1/2, pp.2 - 29

Published online: 30 Nov 2009 *

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