Inverse method for estimating shear stress in machining

• Constitutive response of AISI 1045 for machining simulations is discussed.
• Current split-Hopkinson pressure bar experimental methods are shown to be inadequate.
• Inverse method estimates shear stress, given temperature distribution on chip-tool interface.

An inverse method is presented for estimating 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 is motivated by a model of heat generation in the chip, which is based on a two-zone contact model for friction along the rake face, and an estimate of the steady-state flow of heat into the cutting tool. Given an experimentally determined discrete set of steady-state temperature measurements along the rake face of the tool, it is shown how to estimate the corresponding shear stress distribution on the rake face, even when no friction model is specified.