Year of Publication

2005

Document Type

Thesis

College

Engineering

Department

Mechanical Engineering

First Advisor

I.S. Jawahir

Abstract

Unlike straight turning, the effective cutting conditions and tool geometry in contour turning operations are changing with changing workpiece profile. This causes a wide variation in machining performance such as chip flow and chip breakability during the operation. This thesis presents a new methodology for optimizing the machining performance, namely, chip breakability and surface roughness in contour finish turning operations. First, a computer program to calculate the effective cutting conditions and tool geometry along the contour workpiece profile is developed. Second, a methodology to predict the chip side-flow for complex grooved tool inserts is formulated and integrated in the current predictive model for contour turning operations. Third, experimental databases are established and numerical data interpolation is applied to predict the cutting forces, chip shape and size, and surface roughness for 1045 steel work material. Finally, based on the machining performance predictions, a new optimization program is developed to determine the optimum cutting conditions in contour finish turning operations.

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