ISSN 1068-798X, Russian Engineering Research, 2007, Vol. 27, No. 5, pp. 299–304. © Allerton Press, Inc., 2007.

Original Russian Text © L.S. Sidorenko, 2007, published in STIN, 2007, No. 2, pp. 20–26.

Mathematical Model of Buildup Formation

in Cutting the Steels
L. S. Sidorenko
DOI: 10.3103/S1068798X07050152

For the study of the processes that arise in the metals the course of the fundamental studies of the curve AD
in the course of their working by pressure, by cutting, during the static and dynamic loading–unloading tests
and by other methods, and for selecting the optimal that more complex phenomena, in addition to the elas-
working conditions, it is necessary to use the scientific toplasticity phenomena, develop in the specimens.
results from the fields of physics, continuum mechan- These phenomena include preaction, postaction, relax-
ics, theory of deformation and fracture of the solid bod- ation, creep, latency of the plastic deformation (the lag
ies, cutting theory, and so on. It is well known that the effect), and so on.
processes of the deforming of the bodies by stretching,
compression, shearing, torsion, and bending are associ- In the course of the experimental studies of the ten-
ated with the plastic yield curve. sion diagram, there was discovered on the curve AD the
“resting” phenomenon [3], termed the “yield plateau”
The first studies of the metal deformation process,
performed in the XVII century [1, 2], led to the discov- or the “yield tooth.” This phenomenon is expressed in
ery of the fundamental rheological properties that are the form of the straight line BC, which may be directed
manifest in the metal in the course of its deformation. up (see Fig. 1a) [21], horizontally (see Fig. 1b), or down
Thus, Hooke discovered the phenomenon of elastoplas- [20]. However, it is known [20] that there are metals on
ticity and formulated the first law, expressing the rela- the tension diagram of which there is no definite yield
tionship between the stress and the elastic deformation plateau (see, for example, Fig. 1c). For these metals, we
in tension [1], and the second law for the compression use the engineering stress, for which the residual rela-
process. tive deformation εres = 0.002 to 0.005 (0.2 to 0.5%),
which corresponds to the engineering yield plateau (the
In accordance with these laws, on the elastic seg- engineering yield limit σ0.2 to σ0.5 [20].
ment OA of the tension diagram (Figs. 1a and 1b) there
is a directly proportional linear mathematical relation-
ship between the stress σp and the deformation ε (or σ (a) (b)
between the load P and the relative elongation ∆l). D P
σb D
The analysis of the literature from the various fields
of science (solid body physics [3]; continuum mechan- σs C BC
ics [4, 5, and others]; mechanics of the deformation, σe B
σn A A
elasticity, plasticity, and fracture of the solid body [6 to
19 and others]; the resistance of materials [20 and 21];
the curve AD of the tension diagram that includes the 0 ε 0 ∆l
stress limits σ at the points A (the proportional limit σp), σ, MPa (c)
B (the elastic limit σe), C (the yield limit σs), and D (the 1600
breaking strength σb) was studied experimentally for
48KhNB
1400
many metals only in the XX century with the appear- 10
1200 4KhVS
ance of the precision apparatus for recording the very
small deformation change. However, there are no theo- 1000 U8 30
40 ShKh15
retical equations describing the curve AD in the studies 800 20Kh
[3 to 21 and others). 600
At the present time, in connection with the develop- 400
ment of metal deformation theory, the interest of the 200
scientists and mechanicians in the theoretical studies of 0 0.2 0.4 0.6 0.8
the curve AD has increased, and its study is an urgent q
problem.
Fig. 1. Tension diagrams: (a) typical for the steels [21]; (b)
Rheological phenomena that can be reflected on typical for cast steel [20]; (c) actual for various steels [25]
the curve AD. It was established [20–22 and others] in (q is the relative deformation of the specimen cross section).

299
300
γ Both previously and at the present time, the shrink-
δ1
ρ1
δ and cutting [23–32, 36–38, and others].
ρ
a However, the theoretical formulas that can account
l1 l0
h
Fig. 2. Form of buildup in the principal secant plane of the
cutting edge.
The foregoing rheological phenomena are reflected
on the entire curve from the point A to the point D, at
which failure of the metal starts. It has been established
experimentally that each of these phenomena is charac-
terized by a lag time. Its magnitude T depends on the
conditions of the deformation process, primarily on the
deformation rate and the mechanical properties of the
metal. The time T can be determined experimentally or
calculated.
The analysis of numerous studies shows that the
time T has not been used in the practice of the calcula-
tions of the parameters of the metal working processes
(these parameters include, for example, the chip shrink-
age [23, 24], the contact length [25, 26], the buildup
[27, 28], the cutting forces [25, 29], the temperature
[25, 27–32], and others). In contrast with the process of
the stretching/compression of the metals, in the course
of the machining process phenomena other than the
foregoing take place in the metals. We shall examine
these phenomena briefly for the example of the cutting
process.
Phenomena that arise in cutting the metals. The
development of the machinebuilding industry in the
XIX century required the determining of the optimal
metal working conditions. In this connection, the sys-
tematic study of the phenomena arising in the various
forms of the working of the metals was initiated in the
middle of the XIX century. Thus, it was found that the
elastoplasticity phenomenon that was discovered by
Hooke in the stretching–compression of the metals also
arises in working by pressure and cutting, accompanied
by the shearing processes and by other phenomena.
The phenomenon termed shrinkage of the chip was
described for the first time in [23]. This phenomenon
was determined using an empirical formula without
account for the time T. However, Hooke’s laws were not
used in the proposed theory. In a continuation of the
studies of the machinability of the metals by cutting,
another new phenomenon was discovered (termed the
buildup) that forms on the contact area of the front sur-
face of the tool [27]. However, once again the Hooke’s
SIDORENKO
laws were not used for the mathematical description of
the buildup-formation process.
age and buildup phenomena are basically studied
experimentally. This applies to the various forms and
conditions of pressure working [33 to 35 and others]
for the rheological phenomena taking place with
latency in the calculations of the output parameters for
the indicated working processes have not yet been
obtained. This is primarily explained by the absence of
the precise models describing the complex shaping pro-
cesses.
Phenomena of buildup formation on the tool.
When cutting the ductile steels, in certain conditions
the chip particles adhere to the front surface of the tool,
characterized by the lip angle δ and the cutting edge
rounding radius ρ (the cutting edge length is l0). As a
result, there forms a buildup of length l1 and height h
with the taper angle δ1, the edge rounding radius ρ1, and
zero back angle (Fig. 2).
The nature of the appearance of this phenomenon
was disclosed as a result of the many years of experi-
mental studies of the buildup, conducted by several sci-
entists. It was also established that the buildup shape
and dimensions depend primarily on the following fac-
tors: the cutting speed v, the sheared layer thickness a;
the tool taper angle δ, and the mechanical properties of
the workpiece material. In addition, it was shown
experimentally that the buildup may appear or disap-
pear, depending on the quantities v, a, δ, and also on the
presence or absence of cooling.
It was established experimentally in the well-known
studies [25, 28, 29, 31, and 32] that the cutting speed
has the most significant influence on the buildup
dimensions. Thus, it was shown [25, 28, 29, and 31]
that for each workpiece metal there is a critical cutting
speed vk, at which the buildup is maximal. In [28] there
was proposed the formula vk = Kv /(δaxby) where Kv is
the cutting coefficient; b is the sheared layer width,
mm; a is in mm; δ is in degrees; and vk is in m/s.
The further experiments [31] showed that for certain
conditions of the cutting of the steels, the buildup of the
maximal height is formed with v = 0.35 to 0.5 m/s. The
buildup does not appear at the low (v < 0.15 m/s) and
high (v > 1.35 m/s) cutting speeds. The absence of the
buildup at the low cutting speeds is explained by the
low temperature in the zone of the chip contact with the
tool, and at the high speeds by the high temperature, at
which the metal becomes more plastic and the friction
forces decrease significantly.
The buildup is a positive factor in rough machining,
since it facilitates the chip forming process thanks to
the decrease of the angle δ (i.e., increase of the front
angle γ), and it also protects the blade against the ero-
sive action of the chip, and shields it from the heat that
RUSSIAN ENGINEERING RESEARCH Vol. 27 No. 5 2007
 MATHEMATICAL MODEL OF BUILDUP FORMATION IN CUTTING THE STEELS
is generated in the contacting of the tool with the work-
piece.
The forming of the buildup in the finish machining
process is undesirable, since it leads to degradation of
the quality of the machined surface because of the fact
that the buildup particles adhere tightly to the cutting
surfaces. Moreover, the shearing of the buildup leads to
vibration of the tool, which also degrades the quality of
the surface and shortens the blade service life.
It follows from the literature survey that the analysis
of the buildup formation process has basically a ver-
bal/descriptive nature. The formulas for calculating the
parameters of the buildup that are presented in some
studies are not sufficiently exact. In this connection, the
problem of improving the accuracy of the calculation of
the buildup parameters is urgent; its solution will make
it possible to increase the life of the tool and the quality
of the machined surface by selecting the optimal cut-
ting conditions.
Adoption of the postulates for developing the
buildup size calculation model. Several postulates
have previously been formulated [38], however they
require refinements and a more consistent exposition.
We shall present four refined postulates.
First postulate. It has been established experimen-
tally [25 and 29] that in the course of the shearing of a
layer of thickness a there forms in this layer a curvilin-
ear wedgelike stress–strain zone that consists of a fam-
ily of second-order curves: the stress lines. Shearing of
the chip takes place along one of these lines (the lower
limiting line), which corresponds to the modern con-
cepts of the theory of plasticity and fracture of the solid
bodies [14 to 17 and others].
On this basis, we adopt the following postulate: “As
the theoretical second-order curve approximating the
initial concave boundary of the chip-forming zone, it is
best to take the elliptic curve that is most widely used
in developing the deformation process models and is
used for the calculations of the stresses in cracks.”
We can express in accordance with this postulate the
connection of the semiaxes of the ellipse with the mag-
nitude of the shear zone (SZ), the cutting velocity v, the
sheared layer thickness a, the tool front angle γ, the
Brinell hardness of the metal, and also the rheological
time T (the latency time of the plastic deformation on
the yield plateau).
Second postulate. We shall examine three deforma-
tion schemes (in the processes of stretching, embedding
of the hardness testing ball, and shearing of the chip in
the cutting process) on the basis of the commonality of
the plastic deformation curve BCD (see Fig. 1a and 1b).
It is well known [20, 21, 25, 29, and 37] that in the
deformed solid body with approach to the strength limit
σb there appears a family of stress lines, from which
there are formed the boundary (contour) stress lines in
the form, respectively, of the curvilinear fracture neck,
the circular imprint from the ball, and the chip shearing
curve.
RUSSIAN ENGINEERING RESEARCH Vol. 27 No. 5
301
It has been established [37] that in spite of the seem-
ingly different forms of these contour lines, their
dimensions in certain experimental conditions agree
quite precisely. Then, combining these three contour
lines, we can draw through them a single elliptic line.
We note that the boundary contours coincide under
the following conditions: (1) the length of the neck in
the stretching of the specimen that was selected for the
analysis is equal to the radius of the ball imprint; (2) the
lower chip shearing boundary line coincides with the
axial section of the ball imprint if the cutting speed is
close to zero.
These arguments make it possible to associate the
mechanical properties of the metal (the Brinell hard-
ness) with the ellipse that was adopted in the first pos-
tulate, considering the radius of the ball imprint to be
equal to one of the semiaxes of the ellipse. Thus, we
formulate the following postulate: “The length of the
semiaxis of the elliptic line along which cold shearing
of the chip takes place is equal to the radius of the
imprint of the Brinell instrument ball.” This postulate
makes it possible to take into account the influence of
the mechanical characteristics of the metal on the
buildup dimensions.
Third postulate. It was noted above that the rheo-
logical phenomena take place, both in the cutting of the
metals and in their tension tests. On the basis of the
analysis of these phenomena, we adopt the postulate:
“With increase of the cutting speed, the narrowing of
the curvilinear wedgelike stress–strain chip-forming
zone that is sheared in the cutting process along the
elliptic line is associated with the rheological phenom-
enon of the latency of the plastic deformation, which is
described theoretically by the Maxwell model and
equation.” The calculated latency time T is used as the
parameter in calculating the large semiaxis of the stress
ellipse in the developed fundamental scheme.
Fourth postulate. The analysis of the works
devoted to studying the buildup phenomenon shows
that its length is influenced primarily by the high pres-
sure arising in the course of the time T under the action
of the high shear stress in the chip-forming zone along
the entire elliptic line. Considering the foregoing argu-
ments, we formulate the postulate: “The length of the
buildup in the plastic contact zone on the front surface
of the tool is equal to the length of the elliptic line,
along which the shearing of the chip takes place.”
On the basis of the formulated postulates, there has
been created the fundamental analytic model (Fig. 3),
including the tool 1, the layer that is being sheared 5,
the chip 2, the ellipse 3, the straight line 4 that limits the
thickness of the sheared layer, and the buildup 6. This
model, constructed with account for the rheological
properties of the metals, is refined in comparison with
the model that was proposed in [38]. Then it is neces-
sary to establish the connection of the semiaxes of the
ellipse 3 with the primary input parameters of the cut-
ting process: the cutting velocity v, the mechanical
2007
302
2
A mula (1). To find the conditions of the contraction of the
Z chip-forming zone, it is necessary to extend the semi-
γ studies [1 to 38 and others] the first law: “The length of
3 the chip-forming process is equal to the product of the
δ3
P δ1/2
4 ρ1
B O2 K D
δ1/2
a
V
M G L N Mi hi 0
5 6
3S h
Fig. 3. Scheme for calculating the buildup parameters.
properties HB of the workpiece metal, the thickness of
cut a, and the tool front angle γ.
The rheological connection of the parameters of
the cutting process with the semiaxes of the ellipse.
We note that this question has not been studied in cut-
ting theory [23, 25, 27, 28, and 30]. The connection of
the parameters v, a, γ, and HB with the semiaxes of the
ellipse was first studied in [24]. We shall examine the
primary characteristics of this connection.
One of the central problems of the theory of the
deformation of the solid bodies with dynamic action,
particularly in the cutting process, is the calculation of
the plastic deformation latency time T on the curve
BCD of the stress-deformation diagram (see Fig. 1a and
1b). We note that the rheological time T has been little
studied in plasticity theory [9 and 19]; the same is true
for the relative plastic deformation rate, which is func-
tionally connected with the time T.
It follows from the foregoing third postulate, that the
Maxwell equation [21] of the following form is appli-
cable for determining the length of the large semiaxis of
the elliptic stress–strain zone of the chip-forming pro-
cess
T = σ/ ( Eε̇ ),
where σ is the stress; E is the elastic modulus; and ε̇ is
the relative plastic deformation rate.
SIDORENKO
The process of the contraction of the chip-forming
zone is associated both with the time T and with the cut-
Y 1 ting velocity v. The fundamental model (see Fig. 3) is
based on the principle of the contraction of the ellipse,
the large semiaxis OO1 of which is connected with the
velocity v and the time T that is calculated from the for-
axis OO1. It follows from Fig. 3, that this is possible if
01 we associate the semiaxis OO1 with the velocity v that
C coincides with the vector of the chip motion.
We shall formulate on the basis of the analysis of the
δ2 the large semiaxis of the elliptic stress–strain zone of
deformation rate by the latency time of the plastic
l1 deformation of the solid body.” This law is expressed
analytically by the formula OO1 = L = vT, where v is in
m/s. Since the cutting speed is usually expressed in
δ1 m/min, with account for the tool front angle γ this for-
mula takes the form
δ L = 1000vT /60 + a/ cos γ , (2)
where v is in m/min; T is in seconds; and L is in mm.
The physical connection of the small semiaxis of the
ellipse with the hardness of the workpiece material was
proved rigorously in [24 and 38]. This connection is
reflected in the second postulate, in accordance with
which the small semiaxis length
AO 1 = r = d/2, (3)
where d is the diameter of the imprint of the Brinell
instrument ball.
Calculation of the buildup dimensions. For this
we need to solve a system of two equations: the equa-
tion of the ellipse 3 and the equation of the straight line
4 (see Fig. 3):
y
2 2
z ( y + z tan γ )
-----2 + ----2 = 1; --------------------------- = 1. (4)
L r L – a/ cos γ
Solving the system (4), we obtain the coordinates of
the point B of the intersection of the line of the ellipse
and the straight line (z = BB'; y = O1B'), the values of
which were presented in [38].
1. The calculation of the buildup length l1 is based
on the analysis of the kinematics of the motion of the
chip after shearing and its pressure on the front surface,
where the buildup forms. The calculation of the length
l1 that was proposed earlier [38] required corrections.
Therefore, we shall present the refined calculation
sequence. We obtain from the triangles OBB', OKE, and
(1) BB'E (see Fig. 3)
2 0.5
BO = l 2 = [ z + ( a/ cos γ + z tan γ ) ] .
2
(5)
RUSSIAN ENGINEERING RESEARCH Vol. 27 No. 5 2007
 MATHEMATICAL MODEL OF BUILDUP FORMATION IN CUTTING THE STEELS 303

We find with account for the expression (5)
l 1 = CD + OD = BO cos Φ + OK/ cos γ
= l 2 cos Φ + a/ cos γ ,
where
Φ = arcsin ( BD/BO ) = arcsin ( a/l 2 ).
2. Calculation of the buildup height h. The basis for
the calculation of this parameter is the Mohr theorem
[38], in accordance with which the surface of the
buildup is close to the surface of an ellipse with smooth
transition to a conical surface and to a circle.
We shall examine two calculation conditions. In
accordance with the first condition, we consider that the
outer surface of the buildup coincides with the normal
MBC to the ellipse at the point B, and in accordance
with the second condition this surface coincides with
the variable normal MiC that is positioned at the angle
δ2 to the large semiaxis of the ellipse.
We perform the calculation using the first condition,
considering that L > r, γ > 0, and the tip of the buildup
that is rounded with the radius ρ1 intersects the chip
shearing line OB. In this case h = LO = MO – ML. The
variable buildup height in accordance with the second
condition hi = MiO with δ2 < δ3, where the angle δ3 is
defined in Fig. 3.
For the calculation of the segments MO and ML, we
first divide the surface of the buildup into three basic
zones. We shall consider that the tip is located near the
foot of the buildup (whose contour has the form of a cir-
cle with the radius ρ1), the middle zone has the form of
an ellipse, and the zone adjacent to the front surface is
close to the straight generatrix of the cone.
From these zones there are formed areas of approx-
imately triangular shape, and the sides of these trian-
gles can be calculated with the conditions that were
adopted above. Thus, from the triangle MPO we find
MO = PO/sinδ1, where PO = l1sinδ3; and we determine
l1 from the formula (6). Then we calculate ML = MN –
LN, where MN = NO2/tan(δ1/2); LN = NO2 = ρ1. We find
from the obtained expressions
(6) h = l 1 sin δ 2 / sin δ 1 + ρ 1 – ρ 1 / tan ( δ 1 /2 ). (8)
In formula (8) for the conditions when the buildup
intersects the line OB, we calculate the angle δ1 from
(7) the triangle OMC. However, when the actual buildup
arises on the tool, we determine this angle from the tri-
angle OMi C using the formula
δ 1 = 90° – δ 3 – γ or δ 1 = 90° – δ 2 + γ , (9)
where we find the angle δ3 from the triangle BB'C as
follows:
BB' BB' z
tan δ 3 = --------- = ------------------------ = ----------------------------------------------- . (10)
B'C OC – OB' l 1 + z tan γ – a/ cos γ
We determine the angle δ2 in formula (9) on the
basis of the proposed second law: “On the impossibility
of the intersection of the limiting shear line BO with the
original buildup line, regardless of how the ellipse con-
tracts under the action of the velocity.” As a result, the
following connection of the angles is established:
δ 2 = 0.35δ 3 . (11)
3. Calculation of the buildup radius. This parameter
was examined in detail in [38]; we present the final for-
mula:
2
ρ 1 = [ l 1 sin δ 2 tan ( δ 1 /2 ) ]/ [ tan δ 1 cos ( δ 1 /2 ) ]. (12)
Calculation example. We shall calculate on the
basis of formulas (1) to (12) the buildup height h and
length l1 in turning steel 40 (180 HB and σb = 600 MPa)
by a cutter that is made of the BK6 hard alloy with γ =
10° at v = 0.2 to 2000 m/min, and a = 0.65 mm.
We find from formula (1) T = 0.003 s; in accordance
with formula (2) in this cutting speed interval L = 0.67
to 100 mm; from formula (3) with d = 4.5 mm we find
r = 2.25 mm. We calculate the other parameters from
the formulas (4) to (11). The calculated values of the
buildup length l1 and height h are as follows.

v, mm/min 0.2 30 60 90 120 180 400 800 1000 2000

l1, mm 2.50 1.90 1.66 1.51 1.42 1.29 1.07 0.93 0.89 0.79
h, mm 0.61 0.47 0.41 0.38 0.36 0.32 0.29 0.26 0.26 0.25

We see that in this cutting velocity interval the inten-
sity of the variation of the buildup parameters is differ-
ent. Thus, the length l1 varies from 2.5 to 0.79 mm, i.e.,
it decreases by about 3.2 times, while the height h var-
ies from 0.61 to 0.25 mm, i.e., it decreases by about
2.5 times.
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