Machining Process Simulation

Lecture Unit 5
Analytical-empirical Models – Shear Zone Model of Lee & Shaffer

apl. Prof. PD Dr.-Ing. Dipl.-Inform. Andreas Zabel

 Shear Zone Model of Lee & Shaffer

 Fundamental idea: chip formation modelled by a slip line field (lines directed parallel to largest shear
stresses)
 Triangular, red marked area: one state of stress -> only one stress tensor describes complete area
 Mohr’s circle of stress for evaluation

Rake face Chip Stress free edge

Secondary shear zone chip flow not
(rake face-chip contact) restricted
Tool

Secondary shear zone

(rake face-chip contact)
Flank face Shear plane Primary
shear zone

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 Shear Zone Model of Lee & Shaffer

 Fundamental idea:
 Slip lines: lines directed according to the
maximum shear stresses
 are slip lines, are not
 Set of slip lines in the area of
plastic deformation: slip line-field
 Triangle and portion of : primary shear zone
 Triangle and portion of : secondary shear zone

 Complete area surrounded by

has a homogeneous plastic state, i.e.
can be described by one single 45o
stress tensor
 Plane stress
 Ideal rigid-plastic material behavior
(as in Merchant model)
 Evaluation and derivation of shear plane angle based on MCS

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 Stress Free Edge

 Complete stress state in red area is pressure therefore, MSC left from -axis
 Line = point in MCS: free of stress, chip flow is not restricted
 No normal and no shear stresses in MSC: origin

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 Rotation Directions

 Slip line field model: positive rotation direction clockwise due to left-handed coordinate system
 MCS: positive rotation direction clockwise (cf. lecture unit 2)

+ +

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 Position of the Shear Plane

 Line = point in MCS showing maximum shear stress -> shear plane / primary shear zone
 Two possible positions: or

+ +

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 Position of the Shear Plane

 Line = point in MCS showing maximum shear stress -> shear plane / primary shear zone
 Rotation from to : - 45o in left sketch
 Rotation in MCS: -90o (doubling of the angle)

+ +
-90o
-45o

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 Position of in MSC

 Line = point in MCS

 Angle between and : -45o -> in MCS: -90o
 Modell assumes that shear stress in primay shear zone equals shear stress in secondary shear zone

- 90o

+ -45o +

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Position of in MSC

 Angle between and :

 Rotation from to in left sketch: negative rotation direction-> in MSC negative as well
 describes the stress state in the secondary shear zone

+ +
 Relation:

 Green lines are orthogonal to each other

 Green line is orthogonal to (shear plane) -> shear plane angle:
 Red line parallel to rake face –> rake angle:
 Result:

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 Friction Angle

 Point in MCS describes the stress state in the rake face (secondary shear zone!)
 Split between normal and shear stress determined by friction coefficient, i.e. friction angle
 In MSC:

+ +

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 Final Result: Sheap Plane Angle relation

 MSC: hence:

 (second last slide):

 Result shear plane relation: again only depending on

as in Merchant model

+ +

Zabel 12
Complete Stress State in Shear Zone

Principal stress

Maximum
shear stress

Maximum
shear stress

Principal
stress

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 Application of the Lee & Shaffer Model for Force Calculation

 Assumptions for machining of 1045 steel

 Friction coefficient : 0.3 leads to:
 Yield strength:
 Rake angle :
 Cutting conditions:

 Calculation of shear angle:

 Calculation shear force: compared to Merchant model:

 Calculation of normal force on chip:

compared to Merchant model:

 Calculation of cutting force
from workpiece to chip:
compared to Merchant model:
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 Application of the Lee & Shaffer Model for Force Calculation

 Resulting force:

 Merchant model:

 Cutting force:

 Merchant model:

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 Overview Shear Plane Angle Models

 Ernst and Merchant:

 Merchant:

 Stabler:

 Lee and Shaffer:

 Lee and Shaffer (BUE):

 Hücks 1: und

 Hücks 2:

 : friction angle

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 Limitations of Shear Plane Angle Models

 Derivation by power consideration (e.g. Merchant):

 Does really adjust due to the minimum power energy?
 Is the friction coefficient independent from the shear angle?
 Are the stresses in the shear plane independent from ?

 Lee and Schaffer

 Material ideal plastic (as in Merchant model)
 Shear plane in direction of maximum shear stress -> realistic?

 Stresses in primary shear zone (line, zone) constant

 Many assumptions and limitations

 Simplified geometry

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 Summary

 Repetition: normal- and tangential stresses / MCS

 Shear plane model by Lee und Shaffer

 Derivation
 Evaluation

 Overview of shear plane angle models

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 Literature

 Bryant, M. D. : Physics of Machining. ME 392, University of Austin, Texas

 Oxley, P. L. B.: The Mechanics of Machining: An Analytical Approach

to Assessing Machinability, Ellis Horwood Limited, 1989

 Wright, P. K., Trent, E. M.: Metal Cutting. Butterworth-Heinmann, 2000

 Shaw, M. C.: Metal Cutting Principles, Oxford University Press, 2005

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