Decelerative Cutting of 6061-T9 Aluminum, 65-35 Brass, and TPE Copper With Constant Impact Energy

Abstract

The chip formation process during metal cutting in which the cutting velocity is permitted to decrease freely is examined from an experimental standpoint. Metal cutting data are obtained from a specially constructed decelerative cutting apparatus for 6061-T9 aluminum, 65-35 brass, and TPE copper under the test conditions of constant energy input and variable initial momentum, velocity, and rake angle. The overall mechanics of chip formation are found to be essentially identical to that for the steady state, including a similarity of the dynamic velocity dependence of cutting forces to their velocity dependence in steady state tests. A complex velocity dependence is noted for 6061-T9 Aluminum. Further evidence of the constancy of the dynamic shear stress is presented. Kinetic energy and momentum are found to have no significant effects upon the chip formation process.