Chipping and crushing mechanisms in orthogonal rock cutting
The understanding of rock removal mechanisms, as one of the essential elements for advancing the cutting performance of polycrystalline diamond compact (PDC) cutters, is still incomplete. This paper is seeking to formulate a cutting theory to analytically explain how rock interacts with PDC cutters...
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| Published in | International journal of mechanical sciences Vol. 119; pp. 224 - 236 |
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| Main Authors | , , |
| Format | Journal Article |
| Language | English |
| Published |
Elsevier Ltd
01.12.2016
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| Abstract | The understanding of rock removal mechanisms, as one of the essential elements for advancing the cutting performance of polycrystalline diamond compact (PDC) cutters, is still incomplete. This paper is seeking to formulate a cutting theory to analytically explain how rock interacts with PDC cutters in a simple cutting configuration – linear cutting. In the proposed approach, a rock crushing zone is introduced at the rock-cutter interface beneath the cutter's rake face, namely the Tip Crushing Zone (TCZ), which, as a destruction kernel, is responsible for both the crushing and chipping phenomena occurring in the cutting process. The physical aspects of these two disparate chip formation mechanisms are discussed. Moreover, closed form expressions for the cutting and thrust forces are derived based on the equilibrium of moments and on the minimum chipping energy principle. To evaluate the force model, comprehensive linear rock cutting tests were conducted on a newly developed rock cutting facility. Both the chip formation phenomena and force responses are in good agreement with the newly proposed theory.
•A new cutting theory is proposed to explain rock's cutting and chipping mechanisms•Experimental data is presented in support of force and chip formation predictions.•The predictions of force responses and rock failure behaviors agree with the tests.•The theory provides insights into the optimization of rock cutting processes. |
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| AbstractList | The understanding of rock removal mechanisms, as one of the essential elements for advancing the cutting performance of polycrystalline diamond compact (PDC) cutters, is still incomplete. This paper is seeking to formulate a cutting theory to analytically explain how rock interacts with PDC cutters in a simple cutting configuration - linear cutting. In the proposed approach, a rock crushing zone is introduced at the rock-cutter interface beneath the cutter's rake face, namely the Tip Crushing Zone (TCZ), which, as a destruction kernel, is responsible for both the crushing and chipping phenomena occurring in the cutting process. The physical aspects of these two disparate chip formation mechanisms are discussed. Moreover, closed form expressions for the cutting and thrust forces are derived based on the equilibrium of moments and on the minimum chipping energy principle. To evaluate the force model, comprehensive linear rock cutting tests were conducted on a newly developed rock cutting facility. Both the chip formation phenomena and force responses are in good agreement with the newly proposed theory. The understanding of rock removal mechanisms, as one of the essential elements for advancing the cutting performance of polycrystalline diamond compact (PDC) cutters, is still incomplete. This paper is seeking to formulate a cutting theory to analytically explain how rock interacts with PDC cutters in a simple cutting configuration – linear cutting. In the proposed approach, a rock crushing zone is introduced at the rock-cutter interface beneath the cutter's rake face, namely the Tip Crushing Zone (TCZ), which, as a destruction kernel, is responsible for both the crushing and chipping phenomena occurring in the cutting process. The physical aspects of these two disparate chip formation mechanisms are discussed. Moreover, closed form expressions for the cutting and thrust forces are derived based on the equilibrium of moments and on the minimum chipping energy principle. To evaluate the force model, comprehensive linear rock cutting tests were conducted on a newly developed rock cutting facility. Both the chip formation phenomena and force responses are in good agreement with the newly proposed theory. •A new cutting theory is proposed to explain rock's cutting and chipping mechanisms•Experimental data is presented in support of force and chip formation predictions.•The predictions of force responses and rock failure behaviors agree with the tests.•The theory provides insights into the optimization of rock cutting processes. |
| Author | Zhu, Wu-Le Ehmann, Kornel F. Che, Demeng |
| Author_xml | – sequence: 1 givenname: Demeng surname: Che fullname: Che, Demeng email: dche@u.northwestern.edu – sequence: 2 givenname: Wu-Le surname: Zhu fullname: Zhu, Wu-Le – sequence: 3 givenname: Kornel F. surname: Ehmann fullname: Ehmann, Kornel F. |
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| Cites_doi | 10.1016/0013-7944(90)90269-M 10.1016/0148-9062(65)90018-5 10.1016/0148-9062(72)90027-7 10.1115/MSEC2014-3952 10.1016/j.enggeo.2012.07.011 10.1007/BF00880927 10.1007/s00170-006-0531-5 10.1063/1.1707586 10.1115/MSEC2016-8510 10.1115/MSEC2015-9249 10.1007/BF01019602 10.1016/0890-6955(94)90081-7 10.1016/0148-9062(92)91041-3 10.1115/1.4007623 10.1016/j.ijrmms.2007.02.005 10.1016/S0013-7952(97)00059-8 10.1016/0013-7944(92)90159-C 10.1115/1.4033905 10.1115/1.4007468 10.1016/j.ijrmms.2014.08.014 10.1016/B978-1-4832-8307-4.50053-2 10.2118/14219-MS 10.1115/MSEC2013-1127 10.1115/1.4029653 10.1002/nag.2113 10.1016/S1365-1609(99)00107-0 10.1115/1.4009380 10.1016/0148-9062(95)00027-E |
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| Keywords | Analytical model Cutting mechanics Rock cutting Cutting theory Polycrystalline diamond compact (PDC) cutter Rock removal mechanism |
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| SubjectTerms | Analytical model Chip formation Chipping Crushing Cutters Cutting Cutting mechanics Cutting parameters Cutting theory Mathematical analysis Polycrystalline diamond compact (PDC) cutter Rock Rock cutting Rock removal mechanism |
| Title | Chipping and crushing mechanisms in orthogonal rock cutting |
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