Inverse method for estimating shear stress in machining

• Published in: Journal of the mechanics and physics of solids Vol. 86; pp. 220 - 236
• Main Authors: Burns, T.J., Mates, S.P., Rhorer, R.L., Whitenton, E.P., Basak, D.
• Format: Journal Article
• Language: English
• Published: England Elsevier Ltd 01.01.2016
• Subjects: Abel integral equation; AISI 1045 steel; Contact; Estimates; Estimating; Friction; Inverse method; Machining; Metal cutting; Numerical and analytical modeling; Rake faces; Shear stress; AISI 1045 steel; Numerical and analytical modeling; Friction; Metal cutting; Abel integral equation; numerical and analytical modeling; metal cutting; AISI 1045 Steel; friction
• ISSN: 0022-5096
• DOI: 10.1016/j.jmps.2015.10.008

An inverse method is presented for estimating shear stress in the work material in the region of chip–tool contact along the rake face of the tool during orthogonal machining. The method is motivated by a model of heat generation in the chip, which is based on a two-zone contact model for friction along the rake face, and an estimate of the steady-state flow of heat into the cutting tool. Given an experimentally determined discrete set of steady-state temperature measurements along the rake face of the tool, it is shown how to estimate the corresponding shear stress distribution on the rake face, even when no friction model is specified. •Constitutive response of AISI 1045 for machining simulations is discussed.•Current split-Hopkinson pressure bar experimental methods are shown to be inadequate.•Inverse method estimates shear stress, given temperature distribution on chip-tool interface.