Workpiece material model based predictions for machining processes

In this paper, a methodology for work material constitutive model based calculations of forces, stress and temperature distributions in orthogonal machining are introduced. Oblique moving band heat source theory is utilized and combined with modified Oxley's parallel shear zone theory. Non-uniform heat intensity at the tool-chip interface is obtained from the predicted stress distributions utilizing slip line analysis of the modified secondary shear zone. Model validation is performed by comparing some experimental results with the predictions for machining of AISI 1045 steel and AL 6082-T6. Good agreements with the experiments are observed. A detailed stress and temperature distributions computed analytically is obtained.