Date of Award

8-2016

Document Type

Thesis

Degree Name

Master of Science (MS)

Legacy Department

Mechanical Engineering

Committee Member

Dr. Oliver J Myers, Committee Chair

Committee Member

Dr. Georges M Fadel

Committee Member

Dr. Garrett Pataky

Committee Member

Dr. John E. Wyatt, Mississippi State University

Abstract

Machining is a subtractive production technique for achieving desired shapes from preformed blocks of materials with surface quality and dimensional accuracies. Despite the development of high performance finite-element codes, the simulation of machining remains a complex task due to geometric complexities, high cutting speeds, high temperatures and strain rates that need high simulation times. In the mathematical formulation for machining research, shear angle is one of the most important parameter which helps determining the parameters such as chip velocity, cutting force and the energy requirements which determine the efficiency of a machining operation. From the early machining research and supporting literature it has always been claimed that the shear angle is dependent on the cutting velocity. The research conducted projects the impact of some other machining parameters to be the influencing variables for the shear angle in cutting. In this thesis an in depth investigation has been carried out to understand the impact of tool-chip contact time on the shear angle in an orthogonal machining operation and its numerical modeling by FEM. The success of the FEM of machining is dependent on the material constitutive law that characterizes the thermo-mechanical behavior of the machining tests that have been conducted. The impact of the material constitutive model on the FEM simulations are studied closely. The simulation model setup by using the material constitutive law constants will be compared with the experimentation results. The observed differences with reasons and possible solutions are discussed.

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