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Displaying 1 - 25 of 44

Inverse Method for Estimating Shear Stress in Machining

November 3, 2015
Author(s)
Timothy J. Burns, Steven P. Mates, Richard L. Rhorer, Eric P. Whitenton, Debasis Basak
An inverse method is presented for estimating the shear stress in the work material in the region of chip-tool contact along the rake face of the tool during orthogonal machining. The method uses an estimate of the temperature of the work material as it

Dynamic Flow Stress Measurements for Machining Applications

December 19, 2014
Author(s)
Steven P. Mates, Eran Vax, Richard Rhorer, Michael B. Kennedy, Eric P. Whitenton, Stephen W. Banovic, Timothy J. Burns
Metals undergo a combination of rapid loading and rapid heating during normal and high speed machining processes. Constitutive models for these materials, however, generally lack any information regarding kinetics of thermally-induced transformations, such

Transient Convection-Diffusion Modelling of Peak Temperature in Orthogonal Cutting

August 19, 2012
Author(s)
Timothy J. Burns, Steven P. Mates, Richard L. Rhorer, Eric P. Whitenton, Debasis Basak
Numerical finite-difference simulations of a two-dimensional transient fast convection-slow diffusion model of the temperature field in orthogonal cutting, due to Tlusty, have been shown to provide better predictions of the peak temperature during

Modeling the Peak Cutting Temperature During High-Speed Machining of AISI 1045 Steel

May 22, 2012
Author(s)
Timothy J. Burns, Steven P. Mates, Richard L. Rhorer, Eric P. Whitenton, Debasis Basak
This paper presents new experimental data on AISI 1045 steel from the NIST pulse-heated Kolsky Bar Laboratory. The material is shown to exhibit a stiffer response to compressive loading when it has been rapidly preheated, than it does when it has been

Dynamic Properties for Modeling and Simulation of Machining: Effect of Pearlite to Austenite Phase Transition on Flow Stress in AISI 1075 Steel

January 3, 2011
Author(s)
Timothy J. Burns, Steven P. Mates, Richard L. Rhorer, Eric P. Whitenton, Debasis Basak
The Pulse-Heated Kolsky Bar Laboratory at the National Institute of Standards and Technology (NIST) has been developed for the measurement of dynamic properties of metals. Because high-speed machining processes can lead to extremely rapid heating of a

Effect on Flow Stress of a Rapid Phase Transition in AISI 1045 Steel

July 13, 2010
Author(s)
Timothy J. Burns, Steven P. Mates, Richard L. Rhorer, Eric P. Whitenton, Debasis Basak
New experimental data on AISI 1045 steel from the NIST pulse-heated Kolsky Bar Laboratory are presented. The material is shown to exhibit a nonequilibrium phase transformation at high strain rate. An interesting feature of these data is that the material

Modeling of the Temperature Field in the Chip and in the Tool in High-speed Machining of a Carbon Steel: Effect of Pearlite to Austenite Phase Transition in AISI 1075

April 7, 2010
Author(s)
Timothy J. Burns, Steven P. Mates, Richard L. Rhorer, Eric P. Whitenton, Debasis Basak, Russell H. McFadden
A one-dimensional transient finite-difference model for the temperature distribution in orthogonal metal cutting, which was originally developed by Boothroyd, and then improved upon by Tlusty, is used to calculate the temperature field in the chip and in

An electrical pulse-heated Kosky bar technique for high strain rate flow stress measurements of rapidly heated metals

September 13, 2009
Author(s)
Steven P. Mates, Stephen W. Banovic, Richard L. Rhorer, Timothy J. Burns, Eric P. Whitenton, D Basak
We have developed a unique electrical pulse-heated Kolsky Bar technique for measuring the flow stress of metals at heating rates of up to 6000 °C per second and strain rates up to 10^4 per second. Under these conditions, which are approaching those found

Machining Process Measurements: A Titanium Machining Example

June 4, 2009
Author(s)
Richard L. Rhorer, Eric P. Whitenton, Timothy J. Burns, Steven P. Mates, Jarred C. Heigel, April L. Cooke, Johannes A. Soons, Robert W. Ivester
NOTE: This is a two-page abstract for publication in the CD-ROM conference proceedings only. Oral presentation of the complete paper will be presented at the conference (SEM, June 1-4, 2009, Albuquerque). This paper discusses recent results of studying Ti

Recent Results from the NIST Pulse-Heated Kolsky Bar

September 3, 2007
Author(s)
Timothy J. Burns, Steven Mates, Richard L. Rhorer, Eric P. Whitenton, Debasis Basak
A Kolsky bar laboratory for measuring dynamic material properties, in support of improved finite-element modeling of high-speed machining processes, has been developed at the National Institute of Standards and Technology (NIST). The NIST split-Hopkinson

Tool Length-Dependent Stability Surfaces

April 20, 2004
Author(s)
T L. Schmitz, J C. Ziegert, Timothy J. Burns, Brian S. Dutterer, W R. Winfough
This paper describes the development of three-dimensional stability surfaces, or maps, that combine the traditional dependence of allowable (chatter-free) chip width on spindle speed with the inherent dependence on tool overhang length, due to the

Influence of Heating Rate on Flow Stress in High-Speed Machining Processes

April 1, 2004
Author(s)
Timothy J. Burns, Robert W. Ivester, Michael Kennedy, Richard L. Rhorer, Matthew A. Davies, Howard Yoon, Lyle E. Levine, Richard J. Fields, D Basak, Eric P. Whitenton
For several decades, a major focus of machining research has been the measurement and prediction of temperature. Here, the influence of the rate of heating on the flow stress, and the implications of this for finite-element modeling of high speed metal

Thermal Imaging of Metals in a Kolsky-Bar Apparatus

October 1, 2003
Author(s)
Howard W. Yoon, D Basak, Richard L. Rhorer, Eric P. Whitenton, Timothy J. Burns, Richard J. Fields, Lyle E. Levine
For materials testing at elevated temperatures, we describe the design and the development of a resistively heated Kolsky-bar apparatus. The temperature of the sample is determined by non-contact thermometry and the spatial temperature gradients in the

Kolsky Bar With Electrical Pulse Heating of the Sample

June 1, 2003
Author(s)
Eric P. Whitenton, Michael Kennedy, Matthew A. Davies, Gerald V. Blessing, Brian S. Dutterer, Richard L. Rhorer, Howard W. Yoon, Lyle E. Levine, Richard J. Fields, D Basak, Timothy J. Burns
The accuracy of simulations for modeling of machining processes is often limited due to insufficient knowledge of the material properties during machining, which can involve strain rates on the order of 104 per second or higher, plus rapid material heating

Receptance Coupling for High-Speed Machining Dynamics Prediction

February 1, 2003
Author(s)
T L. Schmitz, Timothy J. Burns
We apply receptance coupling techniques to predict the tool-point frequency response for high-speed machining applications. Building on early work of Duncan, Bishop and Johnson, and more recent work of Ewins, et al., we develop an analytic expression for

Calibrated thermal microscopy of the tool-chp interface in machining

January 1, 2003
Author(s)
Matthew A. Davies, Howard W. Yoon, Tony L. Schmitz, Timothy J. Burns, Michael Kennedy
This paper presents the results of calibrated, microscopic measurement of the temperature fields at the tool-chip interface during the steady-state, orthogonal machining of AISI 1045 steel. The measurement system consists of a nearly diffraction limited

Constitutive Model Data for Machining Simulation Using the NIST Pulse-Heat Kolsky Bar

January 1, 2003
Author(s)
Eric P. Whitenton, Michael Kennedy, Matthew A. Davies, Gerald V. Blessing, Brian S. Dutterer, Richard L. Rhorer, Howard W. Yoon, Richard J. Fields, D Basak, Timothy J. Burns
A new facility for dynamic material testing using a traditional Kolsky bar with the addition of controlled electrical-resistive pulse heating has been established at the National Institute of Standrds and Technology (NIST). Dynamic stress-strain data have