Year of Publication

2008

Document Type

Thesis

College

Engineering

Department

Manufacturing Systems Engineering

First Advisor

I.S. Jawahir

Abstract

This thesis presents the application of topology to machining at the micro and macro levels through an experimental study, modeling and analysis. Uncoated carbide tools of four different cutting edge radii and four different feed rates are used to perform orthogonal machining on AISI 1045 steel disks. The study analyzes the cutting forces, changing grain boundary parameters, micro-hardness, temperature and correlates them to the residual stresses that hold a key to the product life. This analysis helps to understand and evaluate the aspects of grain boundary engineering that influence the fatigue life of a component. The two components of residual stresses (axial and circumferential) are measured, and are correlated with the different cutting edge radii and feed conditions. A topology-based modeling approach is applied to study and understand various outputs in the machining process. The various micro and macro topological parameters that influence the machining process are studied to develop a model to establish the effects of topological parameters in machining using Maple program.

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