ENB331 Lecture Notes - Lecture 3: Elastic Modulus, Milling Cutter, Residual Stress

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Cutting force becomes excessive and/or dynamic leading to brittle fracture. Cutting temperature is too high for the tool material. Fracture and temperature are premature failures; gradual wear is preferred because it leads to the longest possible use of the tool. Gradual wear occurs at two locations on a tool: crater wear occurs on top rake face, flank wear occurs on flank. Schematic illustration of a dull tool with respect to the depth of cut in orthogonal machining (exaggerated). Note that the tool has a positive rake angle, but as the depth of cut decreases, the rake angle effectively can become negative. The tool then simply rides of the workpiece (without cutting) and burnishes its surface; this action raises the workpiece temperature and causes surface residual stress. Taylors tool life equation n and c are parameters that depend on feed, depth of cut, work material, tooling material and the tool life criterion used.

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