Abstract
Tool chip contact length is an important parameter in machining, as it provides an indication of the size of area of interaction between the hot chip and the tool surface and hence the interface heat transfer zone. Heat transfer and thermally activated wear modes usually dominate tool wear in the high speed machining of steels and machining of titanium alloys at most cutting speeds. In this study, existing models for the prediction of tool–chip contact length are reviewed and examined for their suitability in high speed machining of two widely used engineering alloys. Orthogonal turning tests for AISI 1045 steel and Ti6Al4V titanium alloy are conducted for a range of cutting speeds from conventional to high speeds. New contact length models are presented for both materials covering a wide range of cutting speeds. More significantly, these contact length models are appropriate for high speed machining where thermal loads significantly influence process performance. Additionally, the work discusses how the machinability of engineering materials influences the ability to predict contact length.
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Iqbal, S.A., Mativenga, P.T. & Sheikh, M.A. A comparative study of the tool–chip contact length in turning of two engineering alloys for a wide range of cutting speeds. Int J Adv Manuf Technol 42, 30–40 (2009). https://doi.org/10.1007/s00170-008-1582-6
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DOI: https://doi.org/10.1007/s00170-008-1582-6