Collaborative Research: Experimental and Numerical Investigation and Improved Modeling of the Cutting Edge Contribution in Metal Cutting

该合作项目的研究目标是了解刀具刃口周围的速度、应力和温度场，并开发数值和分析模型来预测这些量。该方法包括：(I)通过立体图像的数字图像相关来实验量化刀具刃口周围的速度场和应变率场；(Ii)利用速度场来调整有限元模型并获得应力和温度场；(Iii)利用速度场和应力场来建立可以包含在主流金属切削模型中的滑移线场模型，以预测速度场、应力场和温度场；以及(Iv)将速度场、应力场和温度场与刀具磨损、相变和加工表面的残余应力联系起来。如果成功，这项研究的好处将包括：(I)以滑移线场模型的形式更好地了解刀具刃口周围的变形，该模型基于基本力学原理，可在本科生和研究生课程中教授；(Ii)实验结果，对有兴趣验证和改进机械加工的分析和有限元模型的研究人员有价值；(Iii)用于预测刀具寿命和零件质量的分析模型，可以指导切割工艺、刀具和涂层的设计，从而有助于提高刀具寿命和生产率，在金属切割的工业应用中，以及(Iv)代表不足的学生参与这项研究。

The research objectives of this collaborative project are to understand the velocity, stress and temperature fields around the tool cutting edge and to develop both numerical and analytical models to predict these quantities. The approach involves (i) experimental quantification of the velocity and strain rate field around the cutting edge by digital image correlation of stereoscopic ultra high speed images, (ii) use of the velocity field to tune finite element models and obtain stress and temperature fields, (iii) use of the velocity and stress fields to develop a slip-line field model for the cutting edge effect that can be included into a prevailing model of metal cutting to predict the velocity, stress and temperature fields, and (iv) relating the velocity, stress and temperature fields to tool wear, phase transformations, and residual stress in the machined surface. If successful, the benefits of the research will include (i) improved understanding of the deformation around the cutting edge in the form of slip-line field models grounded in fundamental mechanics principles that can be taught in both undergraduate and graduate courses, (ii) experimental results valuable for researchers interested in validating and improving analytical and finite element models of machining, (iii) analytical models for predicting tool life and part quality that can guide the design of cutting processes, tools and coatings, thereby helping improve tool life and productivity in industrial applications of metal cutting, and (iv) involvement of underrepresented students in this research.