Analysis of a new Segmentation Intensity Ratio “SIR” to characterize the chip segmentation process in machining ductile metals

Atlati, Samir; Haddag, Badis; Nouari, Mohammed; Zenasni, M.

doi:10.1016/j.ijmachtools.2011.05.007

Cited by 79 publications

(44 citation statements)

References 48 publications

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“…For Sun et al [7] and Calamaz et al [11] the rake angle was equal to 151 and −41, respectively. It is worth mentioning that, according to Atlati et al [35] the shear band spacing increases when the rake angle α is reduced. Thus, for a zero rake angle the values of L s of Calamaz et al [11] shown in Fig.…”

Section: Frequency Of Segmentation and Shear Band Spacingmentioning

confidence: 89%

Analysis of adiabatic shear banding in orthogonal cutting of Ti alloy

Miguélez¹,

Soldani²,

Molinari³

2013

International Journal of Mechanical Sciences

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This work is focused on the numerical analysis of adiabatic shear banding in orthogonal cutting of Ti6Al4V alloy. Segmented chip results from adiabatic shear banding, depending on the competition of thermal softening and strain and strain rate hardening. The influence of cutting velocity and feed in the chip segmentation is studied. Also the role of friction at the tool-chip interface and the effect of rheological parameters of the constitutive equation are analyzed. Experimental tests obtained from previous work of the authors [Molinari A, Musquar C, Sutter G, Adiabatic shear banding in high speed machining of Ti-6Al-4V experiments and modeling, Int J Plast, vol. 18, 2002, p. 443-459] and others were used as a reference to validate the models. Cutting forces and the mechanism of plastic flow localization are analyzed in terms of frequency of segmentation and shear band width and compared to experimental data.

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Section: Frequency Of Segmentation and Shear Band Spacingmentioning

confidence: 89%

Analysis of adiabatic shear banding in orthogonal cutting of Ti alloy

Miguélez¹,

Soldani²,

Molinari³

2013

International Journal of Mechanical Sciences

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“…Another way to quantify chip segmentation was introduced by Atlati et al (2011) using a segment intensity ratio (SIR). SIR is defined as the ratio of average plastic strain inside the shear band to the average plastic strain outside the shear band, i.e., in out SIR .…”

Section: Chip Morphology Analysismentioning

confidence: 99%

Chip morphology predictions while machining hardened tool steel using finite element and smoothed particles hydrodynamics methods

Umer

Qudeiri

Ashfaq

2016

J. Zhejiang Univ. Sci. A

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Chip morphology predictions in metal cutting have always been challenging because of the complexity of the various multiphysical phenomena that occur across the tool-chip interface. An accurate prediction of chip morphology is a key factor in the assessment of a particular machining operation with regard to both tool performance and workpiece quality. Although finite element (FE) models are being developed over the last two decades, their capabilities in modeling correct material flow around the tool tip with shear localization are very limited. FE models with an arbitrary Lagrangian Eulerian (ALE) approach are able to simulate correct material flow around the tool tip. However, these models are unable to predict any shear localization based on material flow criteria. On the other hand, FE models with a Lagrangian formulation can simulate shear localization in the chip segments; they need to make use of a mesh-based chip separation criterion that significantly affects material flow around the tool tip. In this study a mesh-free method viz. smoothed particles hydrodynamics (SPH) is implemented to simulate shear localization in the chip while machining hardened steel. Unlike other SPH models developed by some researchers, this model is based on a renormalized formulation that can consider frictional stresses along the tool-chip interface giving a realistic chip shape and material flow. SPH models with different cutting parameters are compared with the traditional FE models and it has been found that the SPH models are good for predicting shear localized chips and do not need any geometric or mesh-based chip separation criteria.

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“…The parallel-sided shear zone model used by Oxley and Welsh (1963) considered a PSZ thickness that was and the integrity of machining surface. To characterize the serrated chip shape geometrically, Molinari et al (2013) defined the segmentation index, Sutter and List (2013) defined the degree of segmentation, and Atlati et al (2011) defined the segmentation intensity ratio. These scholars showed that the frequency of chip segmentation is related to the cutting speed.…”

Section: Introductionmentioning

confidence: 99%

The chip-flow behaviors and formation mechanisms in the orthogonal cutting process of Ti6Al4V alloy

Chen

Shuang

2017

Journal of the Mechanics and Physics of Solids

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A B S T R A C TThis work involves experimental and analytical investigations of chip flow stability in metal cutting process. First, in cutting experiments of Ti6Al4V alloy, the transformation of chip morphology from continuous to serrated and later to discontinuous was observed as the cutting speed increased. Scanning electron microscopic (SEM) observation of the shear fracture surface demonstrated shear-localized instability and intergranular failure behaviors. Then we used the improved orthogonal cutting model (OCM) to analyze the plastic flow process of work materials in a plane strain state. A corresponding governing equation system was set up, the dimensionless governing parameters were determined by dimensional analysis, and an instability criterion was established by linear perturbation analysis. Analytical results showed that the plastic instability of chip flow could take place in a continuous chip, which is different from the shear-localized instability in a serrated chip. Finally, in terms of the balance conditions between the kinetic energy and the surface energy, the sawtooth growth behavior in serrated chips and the formation mechanism of discontinuous chips were studied.

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Analysis of a new Segmentation Intensity Ratio “SIR” to characterize the chip segmentation process in machining ductile metals

Cited by 79 publications

References 48 publications

Analysis of adiabatic shear banding in orthogonal cutting of Ti alloy

Analysis of adiabatic shear banding in orthogonal cutting of Ti alloy

Chip morphology predictions while machining hardened tool steel using finite element and smoothed particles hydrodynamics methods

The chip-flow behaviors and formation mechanisms in the orthogonal cutting process of Ti6Al4V alloy

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