Progressive tool wear alters the micro geometry of the cutting tool. Of all the tool wear types, flank wear attracted maximum attention as it is often used for determining the tool life. Many researchers agreed to the presence of nonzero inclination of flank wear land with respect to cutting direction but, no research available provides the effect of flank wear land inclination on the attributes of the orthogonal machining.

1. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 4, April (2014), pp. 23-30 © IAEME
23
INFLUENCE OF FLANK WEAR LAND INCLINATION ON ATTRIBUTES
OF ORTHOGONAL MACHINING USING SLIP LINE FIELD
1*
VISHALDATT V KOHIR, 2
S T DUNDUR
1*
Associate Professor, Department of Mechanical Engineering, Angadi Institute of Technology and
Management, Savagaon, Belgaum- 590 009, Karnataka, India
2
Professor, Department of Industrial and Production Engineering, Basaveshawar Engineering
college, Bagalkot, Karnataka, India
ABSTRACT
Progressive tool wear alters the micro geometry of the cutting tool. Of all the tool wear types,
flank wear attracted maximum attention as it is often used for determining the tool life. Many
researchers agreed to the presence of nonzero inclination of flank wear land with respect to cutting
direction but, no research available provides the effect of flank wear land inclination on the attributes
of the orthogonal machining. Hence this paper is targeted to investigate the influence of flank wear
land inclination angle on orthogonal machining using slip line field model. The investigation verifies
the influence of non-zero inclination of flank wear land inclination on the attributes of the orthogonal
machining.
Keywords: Flank Wear Land Inclination, Slip Line, Edge Preparation.
1. INTRODUCTION
In modern manufacturing industry, titanium, nickel and metal matrix composites have
become common work piece materials replacing the conventional ferrous materials. Which are
difficult to machine. One of the main issues with machining of these materials is wear rates of
cutting tool used. Out of all tool wear types, flank wear greatly influences the surface integrity of the
work. Apart from this emergence of new machining technique like hard turning and widespread use
of edge preparation such as chamfered, radiused, honed and water fall honed to strengthened the
edge inspires modern research community to have better understanding of flank wear related
problems to incorporate these tooling characteristics into improve related models or to develop new
cutting models[1]. Slip line field theory was successfully used to construct the cutting models with
different tool edge conditions such as sharp [2- 5], rounded [6-12], chamfered [13, 14], worn or flank
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2. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
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wear [15,16]. According slip line field theory edge prepared tools can be modeled similarly as that of
cutting with a flank wear. Some of the researchers [1, 17, 18, 19] consider that the flank wear is
parallel to the cutting direction. There is another class of researchers [15, 16, 20, 21] who believe
that the flank wear land makes a non zero inclination with the cutting direction as shown in Fig 1
Figure 1: Flank Wear Land Inclination with cutting direction
Generally the cutting edge geometry defined by the edge radius, chamfer angle, or flank wear
considerably influences the material flow pattern in metal cutting [20]. The existence of inclination
of flank wear land was based on observations made by Thomsen and Kobyashi [22], who reported a
significant plastic flow below worn tool flank face when a negative clearance angle exists but for
zero clearance angle wear land does not affect the shearing mechanism. Liu and Barash [17]
indirectly showed the evidence of existence of plastic flow in the work piece under the tool flank
face, while studying the state of sub layer cutting with artificially created flank wear land.
Photomicrograph of the work piece taken by Nakayama [23] provides the evidence of plastic
deformation below the flank surface. Using the above mentioned observations Shi and Ramlingam
[15] developed a slipline model with a chip breaker and flank wear land. A nonzero inclination of
flank wear land with respect to the cutting direction is assumed and the inclination angle is
determined as a part of the problem solution. Waldorf [8] pooled the model of Shi and Ramalingam
[15] with the findings of Thomsen et al. [22] to analyse round edge tools that form sharp-like edges
after stable build up. To predict cutting forces under the combined effects of flank and crater wear, a
slip line based force modeling approach is employed by Yong Huang [20]. In the proposed slipline
field model flank wear land is considered to be inclined to the cutting direction. Slip line field
solutions for a tool with flank wear land making a non-zero inclination with the cutting direction
were proposed by the S T Dundur and N S Das [15] and found that the ploughing, cutting and thrust
forces vary linearly with flank wear. In above mentioned models the inclination of flank wear was
determined as a part solution and no experimental evidence was available. Recently experimental
investigation conducted by Vishaldatt and S T Dundur [24] with a modified single point tool to
capture the profile of flank wear land endorses the non-zero inclination of the flank wear land with
cutting direction. The Fig 2(a) shows the image of tool seen in the Nikon V-12B profile projector
with the magnification of 20 X and Fig 2(b) with annotations. This experimental evidence proves the
existence of non- zero inclination of flank wear land with direction. In this paper an attempt is made
to investigate the consequences of the flank wear land inclination on the attributes of orthogonal
cutting using slipline field solutions.

3. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976
ISSN 0976 – 6359(Online), Volume 5, Issue
Figure 2(a): Image of worn tool
2. SLIP LINE MODEL OF TOOL WITH FLANK WEAR LAND
To study the influence of flank wear land inclination
Dundur and N S Das [15] are utilized.
shear zone OQDF, secondary shear zones
the pre-deformation zone OGH with its free surface
slip line fields are analyzed by the matrix procedure developed
Dewhurst [26]. The corresponding hodo
A FORTRAN program is developed for
flank wear land inclination as one of the input data
slip line field variables angels α, θ,
evaluates the friction angle ϕR then determines the linear coefficient m
within the secondary zone of the slip line field. The value of m
and θ used to construct adhesion and other matrix operators. Then plastic force components Hp,
and moment Mp are determined with
Dewhurst [26]. The solution takes account of for
equilibrium of the chip as per S T Dundur and N S Das
forces are HE, VE and moment ME are calculated. The static admissibility condition of the chip is met
when the following conditions are satisfied.
Where LH and LV are the horizontal and vertical distances of
ensure that adhesion friction condition also reveals at the flank wear land
national Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976
6359(Online), Volume 5, Issue 4, April (2014), pp. 23-30 © IAEME
25
worn tool Figure 2(b): Image of worn tool with annotations
2. SLIP LINE MODEL OF TOOL WITH FLANK WEAR LAND
To study the influence of flank wear land inclination, slip line field solution given by the S T
] are utilized. The Slip line field shown in Fig .3 (a) consists of the primary
, secondary shear zones PQR and QCB, two center fan fields OGF
with its free surface OH inclined to the horizontal at angle
line fields are analyzed by the matrix procedure developed by Dewhurst and Colloins [25]
. The corresponding hodograph is shown in Fig 3 (b).
program is developed for the construction of the proposed slip line field
ear land inclination as one of the input data. The slip line field solutions are characterized by
, ψ2, δ and the hydrostatic pressure pR at R. The program first
then determines the linear coefficient m0 which relates
within the secondary zone of the slip line field. The value of m0 together with the fi
used to construct adhesion and other matrix operators. Then plastic force components Hp,
d moment Mp are determined with help of subroutines given in Dewhurst and Collins
. The solution takes account of forces in elastic contact zone for force and moment
S T Dundur and N S Das [6]. For given PR and X values the elastic
are calculated. The static admissibility condition of the chip is met
following conditions are satisfied.
……………………………………………………………… (1)
…………………………………………………………….... (
………………………………………………
are the horizontal and vertical distances of A from P as shown in Figure 3
friction condition also reveals at the flank wear land QB.
……………………………. (4)
national Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
Image of worn tool with annotations
slip line field solution given by the S T
(a) consists of the primary
OGF and QCD and
inclined to the horizontal at angle φ. The
by Dewhurst and Colloins [25] and
the construction of the proposed slip line field with
The slip line field solutions are characterized by
. The program first
which relates α and β lines
together with the field angles ϕR, α
used to construct adhesion and other matrix operators. Then plastic force components Hp, Vp
help of subroutines given in Dewhurst and Collins [25] and
ces in elastic contact zone for force and moment
and X values the elastic
are calculated. The static admissibility condition of the chip is met
……………………………………………………………… (1)
…………………………………………………………….... (2)
……………………………………………… (3)
as shown in Figure 3(c).To
……………………………. (4)

4. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 4, April (2014), pp. 23-30 © IAEME
26
Figure 3: (a) Slip line field (b) Hodograph (c) forces and moments at the chip boundary
The adhesion friction condition is considered at the work and flank interface as suggested by
Maekawa et al.[27] and same is introduced as the fourth constrain. Which provides the friction angle
at B i.e. ϕB.
2.1 DETERMINATION OF FLANK WEAR LAND INCLINATION FROM SLIP LINE AND
HODOGRAPH
To evaluate the flank wear land inclination or negative clearance angle consider the upper
triangle xhd’ and lower triangle xgd’ of the hodograph fig 2 (b). Applying sine rule we have

5. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 4, April (2014), pp. 23-30 © IAEME
27
ܸܿ ൌ
ఘభ
ୱ୧୬ ఝ
ൈ sin ቀ
ଷగ
ସ
ቁ ൌ
ఘభ
ୱ୧୬ ఋ
ൈ sinሺ‫݀݁ݔ‬′ሻ
sin ߜ ൌ √2 sin ߮ sin൫ߨ െ ሺߜ ൅ ߰ଶ െ ߶ொ െ ߛሻ൯
sin ߜ ൌ √2 sin ߮ sin ߶஻
The above relation is used in the equilibrium equations as fifth condition
‫ܨ‬ହ ൌ sin ߜ െ √2 sin ߮ sin ߶஻ ൌ 0…………………………..……………………….(5)
The above equations (1) to (5) are nonlinear in nature, they are solved using the algorithm
developed by Powell [28] .The chip equilibrium was assumed to be achieved when the inequality
given below is satisfied
൬
‫ܨ‬ଵ
݇‫ݐ‬௢
൰
ଶ
൅ ൬
‫ܨ‬ଶ
݇‫ݐ‬଴
൰
ଶ
൅ ൬
‫ܨ‬ଷ
݇‫ݐ‬௢
൰
ଶ
൅ ൬
‫ܨ‬ସ
݇‫ݐ‬௢
൰
ଶ
൅ ൬
‫ܨ‬ହ
݇‫ݐ‬௢
൰
ଶ
൑ 10ିଵ଴
Normalization by to is to avoid a trivial situation when α and θ are too small and the error
allowed (10ିଵ଴
) is limited by the dimensions of the matrix operators used. Based on Hill’s over
stressing criteria[29] the program terminates and final set of values of slip line are generated. In this
manner all field variables are computed. These data were used to construct the slip line field and
hodograph, to calculate the machining parameters and flank wear land inclination with cutting
direction.
3. RESULTS AND DISCUSSION
In the present study the flank inclination is based on the adhesion friction conditions as
suggested by Maekawa et al.[27]. In this investigative analysis two values of µ are considered while
keeping all other factors constant. It is a well know fact that rake angle plays a vital role in the
machining operation. So the effect of rake angle was considered in Fig.4. The flank wear land angle
decreases with increase in rake angle and this may be due to the increased sharpness of the tool.
During studying the influence of flank wear land inclination by employing the second order response
method using central composite design,
Figure 4: The effect of flank wear land inclination on rake angle
on the Vishal datt and S T Dundur [30] observed the similar trend. It is evident from the Fig.4 that,
friction conditions prevailing at the flank face and work face influence the initial inclination of the
flank face.
0
2
4
6
8
0 5 10 15 20 25
Flankwearlandinclination
Rake angle
µ =2
µ =1

6. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 4, April (2014), pp. 23-30 © IAEME
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Figure 5: The effect of flank wear land inclination on the uncut chip thickness
The chip thickness declines with the rise in flank wear land inclination as shown in Fig. 5.
The cutting force rises as the flank wear land inclination increases as shown in Fig.6. The rise in the
cutting force may be attributed to presence of ploughing forces due to the flank
Figure 6: The effect of flank wear land inclination on the cutting force
wear. At the lower coefficient of friction the variation in the cutting forces is linear but at higher
values this variation becomes very sharp. Similar trend is seen for thrust force in Fig.7.
Figure 7: The effect of flank wear land inclination on the thrust force
Figure 8: The effect of flank wear land inclination on subsurface deformation
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
0 2 4 6 8
Uncutcthipthicness
Flank wear land inclination
µ =1
µ =2
0
2
4
6
8
0 2 4 6 8
CuttingforceFc/to
Flank wear land inclination
µ =2
µ =1
0
2
4
6
8
0 2 4 6 8
ThrustforceFt/to
Flank wear land inclination
µ =2
µ = 1
0
0.2
0.4
0.6
0.8
1
-1 1 3 5 7
Subsurfaceplastic
deformation
Flank wear land inclination

7. International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 4, April (2014), pp. 23-30 © IAEME
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The surface below the flank face is subjected to plastic deformation. This deformation zone
has a bearing on the surface integrity of the work piece. From the Fig 8 it is evident that the rise in
flank wear land inclination increases the sub surface deformation below the flank face.
4. CONCLUSIONS
The usage of non zero flank wear land inclination in the analysis of slip line field theory is
supported by experimental evidences. The present investigation verifies the influence of non-zero
inclination made by the flank face with respect to cutting direction, on the attributes of the
orthogonal machining. The higher values of rake angle result in lower values of inclination angle.
The machining forces and subsurface deformation are affected by the flank wear land inclination.
Present study may lay the foundation for further modeling of machining to address effect of flank
inclination in orthogonal machining.
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