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Chip-Controlled 3-D Complex Cutting Tool Insert Design and Virtual Manufacturing Simulation Shizhuang Luo Iowa State University

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Chip-Controlled 3-D Complex Cutting Tool Insert Design and Virtual Manufacturing Simulation Shizhuang Luo Iowa State University Iowa State University Capstones, Theses and Retrospective Theses and Dissertations Dissertations 1999 Chip-controlled 3-D complex cutting tool insert design and virtual manufacturing simulation Shizhuang Luo Iowa State University Follow this and additional works at: https://lib.dr.iastate.edu/rtd Part of the Applied Mechanics Commons, and the Operational Research Commons Recommended Citation Luo, Shizhuang, "Chip-controlled 3-D complex cutting tool insert design and virtual manufacturing simulation " (1999). Retrospective Theses and Dissertations. 12150. https://lib.dr.iastate.edu/rtd/12150 This Dissertation is brought to you for free and open access by the Iowa State University Capstones, Theses and Dissertations at Iowa State University Digital Repository. It has been accepted for inclusion in Retrospective Theses and Dissertations by an authorized administrator of Iowa State University Digital Repository. For more information, please contact [email protected]. INFORMATION TO USERS This manuscript has been reproduced from the microfilm master. UMI films the text directly from the original or copy submitted. Thus, some thesis and dissertation copies are in typewriter face, while others may be from any type of computer printer. The quality of this reproduction is dependent upon the quality of the copy submitted. Broken or indistinct print, colored or poor quality illustrations and photographs, print bleedthrough, substandard margins, and improper alignment can adversely affect reproduction. In the unlikely event that the author did not send UMI a complete manuscript and there are missing pages, these will be noted. Also, if unauthorized copyright material had to be removed, a note will indicate the deletion. Oversize materials (e.g., maps, drawings, charts) are reproduced by sectioning the original, beginning at the upper left-hand comer and continuing from left to right in equal sections with small overiaps. Each original is also photographed in one exposure and is included in reduced form at the back of the book. Photographs included in the original manuscript have been reproduced xerographically in this copy. Higher quality 6" x 9" black and white photographic prints are available for any photographs or illustrations appearing in this copy for an additional charge. Contact UMI directly to order. Bell & Howell Information and Learning 300 North Zeeb Road, Ann Arioor, Ml 48106-1346 USA 800-521-0600 Chip-controlled 3-D complex cutting tool insert design and virtual manufacturing simulation by Shizhuang Luo A dissertation submitted to the graduate faculty in partial fulfillment of the requirements for the degree of DOCTOR OF PHILOSOPHY Major: Mechanical Engineering Major Professor: X. Daniel Fang Iowa State University Ames, Iowa 1999 Copyright © Shizhuang Luo, 1999. All rights reserved. UMI Nuxdser: 9940222 Copyright 1999 by Luo, Shi zhuemg All rights reserved. UMI Microform 9940222 Copyright 1999, by UMI Company. All rights reserved. This microform edition is protected against unauthorized copying under Title 17, United States Code. UMI 300 North Zeeb Road Ann Arbor, MI 48103 ii Graduate College Iowa State University This is to certify that the Doctoral dissertation of Shizhuang Luc has met the dissertation requirements of Iowa State University Signature was redacted for privacy. Major Professor Signature was redacted for privacy. TO gram Signature was redacted for privacy. For the Graduate CoUege iii TABLE OF CONTENTS ABSTRACT vi CHAPTER 1 INTRODUCTION 1 1.1 Scope of the dissertation 1 1.2 Background of the cutting tool design 3 1.2.1 Cutting tool geometry 5 1.2.1.1 Basic single-point tools; flat rake face 5 1.2.1.2 Modified tools: 2-D modification 7 1.2.1.3 Complex tool inserts: 3-D modification 8 1.2.2 Cutting tool material design 10 1.3 Development of the design theories 11 CHAPTER 2 LITERATURE REVIEW ON CHIP CONTROL 15 2.1 Chip control importance 15 2.2 Basic chip forms 16 2.3 Chip formation: chip flow and chip curling 18 2.3.1 Chip side-flow and chip side-curl 19 2.3.2 Chip back-flow and chip up-curl 22 2.3.2.1 Chip back-flow 22 2.3.2.2 Chip up-curl 24 2.3.3 Other research work on chip formation 26 2.3.3.1 Cutting forces models 26 2.3.3.2 Chip formation for special tool shape 27 2.3.3.3 Cutting tool temperature 28 2.3.3.4 Chip formation with different material 28 2.4 Chip breaking 29 2.5 Chip control method 31 2.5.1 Chip classification 31 2.5.2 Chip modeUng: 2-D cyclic chip 33 2.5.3 Chip modeling: 3-D chip 35 2.5.4 Chip control 39 CHAPTER 3 CHIP MODELS FOR COMPLEX GROOVE 41 3.1 Current gap in chip simulation model for complex groove tools 41 3.2 New kinematic model for groove tools 44 3.2.1 A kinematic model considering complex groove geometry 44 3.2.1.1 The chip motion and angular velocities of the helical chip 45 3.2.1.2 Derivation of the kinematic analytic model 49 3.2.2 Analysis of the kinematic model 52 3.2.2.1 Model assumptions 53 3.2.2.2 Complex groove shape factors 54 3.3 Mathematical modeling of the cutting tests 57 iv 3.3.1 Hypothesis from current 2-D and 3-D cutting knowledge 58 3.3.2 Cutting experiments 59 3.3.3 Cutting experimental results 61 3.3.4 Mathematical modeling 64 CHAPTER 4 CHIP-CONTROLLED FEATURE DESIGN FOR CUTTING TOOL INSERT 71 4.1 Modeling the design process 71 4.2 Feature-based design for complex tool insert 77 4.2.1 NURBS as a powerftil surface modeling tool 78 4.2.1.1 NURBS definitions 78 4.2.1.2 Freeform surface generation with NURBS surface 80 4.2.2 Application of tool surface features into the design process 81 4.2.3 Feature surfaces integration 84 4.2.4 Customized design application 84 4.3 Integrating chip control into the design process 87 4.4 Case study of predicted chip chart and real cutting test 89 CHAPTER 5 VIRTUAL REALITY AS AN EMERGING SIMULATION TOOL 93 5.1 Introduction to Virtual reality 93 5.2 Stereoscopic model for graphical display 95 5.2.1 Human eye stereo viewing theory 95 5.2.2 How the stereo glasses provide stereoscopic cue 96 5.3 Literature review on VR as an emerging simulation tool 98 CHAPTER 6 VR AS A TEST-BED FOR CHIP CONTROL SIMULATION 99 6.1 The need of VR as a model testing platform for chip-controlled insert design 99 6.2 The system components for a virtual model testbed 100 6.3 Schematic design of manufacturing simulation 101 6.4 Development of the virtual machining lab 106 6.4.1 Surface roughness prediction 106 6.4.2 NC G-code engine 107 6.4.3 Geometric calculation in lathe 109 6.5 Virtual machining lab development 110 CHAPTER 7 CONCLUSIONS AND DISCUSSIONS 113 APPENDIX 1 EXPERIMENTAL DATA OF CUTTING TESTS 116 APPENDIX 2 LEAST SQUARE METHODS AND STATISTIC ANALYSIS 126 REFERENCES 132 V ACKNOWLEDGEMENTS I would like to thank my major professor. Dr. X Daniel Fang, for his supervision and generous assistance and encouragement during the period of this study. I am grateful to all members in my graduate program of study committee for their invaluable advice on my graduate study. I would also like to acknowledge the generous assistance given by other staff of the department, especially Mr. Larry Couture. vi ABSTRACT Designing suitable tools for the turning operation is of vital interest to manufacturers. The tool inserts used nowadays adopt complex geometric shapes. A question facing many manufacturers is how to effectively design complex shaped tool inserts and how to prove the validity of such design. One of the important criteria for selecting inserts is the ability to control ciiip formation and chip breaking. The research work described in this dissertation attempted to bring innovation into the cutting tool insert design process by using feature-based modeling and by proposing a predictive chip model and integrating it into the design process. Such model integration makes the tool insert design a much more effective process and also enhances the decision­ making required in insert design A new 3-D kinematic chip model was developed to depict chip behavior in a complex groove insert. The model derived showed the analytical relationships between chip shape parameters and chip motion parameters. This dissertation explained how the kinematic model could be modified to take into account all possible 3-D complex groove shapes. A mathematical model was also developed from experimental data to serve the ciurent need for cutting tool design. Other research work presented in this dissertation is the simulation of the machining process in a virtual environment. The virtual machining simulation can be of great benefit for researchers in manufacturing to use the platform as a testbed for product development and testing. 1 CHAPTER 1 INTRODUCTION 1.1 Scope of the dissertation Machining is a key activity in a manufacturing environment. Within machining processes, the lathe turning operation is a major component of the manufacturing process. Designing suitable tools for the turning operation is of vital interest to the manufacturers. With the advance of machining technology, and especially with the introduction of high speed cutting, the requirements of cutting tools have become more demanding than ever before. The tool inserts used nowadays adopt complex geometric shapes. A question facing many manufacturers is how to effectively design complex shaped tool inserts and how to prove the validity of such design. Modem CAD tools are quite powerful in assisting with design visualization. These software packages, however, have no knowledge of the functionality of a specific design.
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