Chip Formation in the Machining of Hardened Steel

Shaw, M. C.; Vyas, A.

doi:10.1016/s0007-8506(07)62385-3

Cited by 176 publications

(79 citation statements)

References 13 publications

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“…discontinuous chip, segmented chip) and roughness patterns that occur on chip surfaces. These features have been attributed variously to adiabatic shear localization [20,21], ductile fracture [13,22], shearing by 'stack-of-cards' type slip [1], inhomogeneous micro-scale plastic flow [14,23], machine stiffness [8] and bifurcative instability [24], all with common underlying features of unsteady flow and non-uniform deformation. The diverse chip morphologies are not unique to metals but have been observed also in cutting of materials such as glass [25], metallic glasses, polymers [26] and paraffin wax [27].…”

Section: Introductionmentioning

confidence: 99%

In situ analysis of flow dynamics and deformation fields in cutting and sliding of metals

2015

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The flow dynamics, deformation fields and chip-particle formation in cutting and sliding of metals are analysed, in situ , using high-speed imaging and particle image velocimetry. The model system is a brass workpiece loaded against a wedge indenter at low speeds. At large negative rake angles, the flow is steady with a prow of material forming ahead of the indenter. There is no material removal and a uniformly strained layer develops on the workpiece surface—the pure sliding regime. When the rake angle is less negative, the flow becomes unsteady, triggered by formation of a crack on the prow free surface and material removal ensuing—the cutting regime. The strain on the prow surface at crack initiation is found to be constant. Chip morphologies, such as discrete particle, segmented chip and continuous chip with mesoscale roughness, are shown to arise from a universal mechanism involving propagation of the prow crack, but to different distances towards the indenter tip. The simple shear deformation in continuous chip formation shows small-angle oscillations also linked to the prow crack. Implications for material removal processes and ductile failure are discussed.

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Section: Introductionmentioning

confidence: 99%

In situ analysis of flow dynamics and deformation fields in cutting and sliding of metals

2015

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“…The mechanism for the onset of serrated chip flow has been extensively studied [7][8][9][10][11][12], and for most ductile metallic materials, the emergence of serrated chip flow is found be related to the thermoplastic shear instability occurred in the primary shear zone (PSZ) [8,9], which is often referred to the formation of adiabatic shear band [13][14][15][16]. And thus, considerable efforts have been carried out to focus on the adiabatic shear localization in the serrated chip formation process, and several classical theoretical models have been developed to predict the onset of serrated chip flow.…”

Section: Introductionmentioning

confidence: 99%

Critical cutting speed for onset of serrated chip flow in high speed machining

Chen

Xue

et al. 2014

International Journal of Machine Tools and Manufacture

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“…At the lower cutting speeds, a minor fracture is initiated on the outer surface of the chip where the normal stress on the shear plane is very low [16]. Further, the minor fracture propagates to a certain distance as facilitated by compressive stresses on the shear plane [17] and usually gets terminated near grain boundaries (indicated by arrows in Fig. 4a).…”

Section: Model Of Chip Formation At Lower Cutting Speedsmentioning

confidence: 99%

“…Since they contain ferrous as well non-ferrous components, there are no specific cutting tools for their machining, as most of the cutting tools are for either ferrous or non-ferrous materials. Secondly, the mechanisms of machining of ferrous as well as non-ferrous materials are known to be different [15][16][17]. Aluminides containing ferrous as well as non-ferrous components form a special case.…”

Section: Introductionmentioning

confidence: 99%

Machining aspects of a high carbon Fe3Al alloy

Chowdhuri¹,

Joshi²,

Rao³

et al. 2004

Journal of Materials Processing Technology

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Iron aluminide alloys containing both ferrous as well as non-ferrous (aluminum) components form unique materials from machining theory and practice point of view. While the cutting tool materials specifically required for their machining are not available, the mechanism of machining of such materials containing ferrous and non-ferrous components has not been adequately investigated. This paper deals with fundamental aspects of chip formation and tool-life in machining of an iron aluminide, Fe 3 Al alloy. Microstructural analysis of chips shows that the interaction of chip and tool in the secondary deformation zone, dependent upon the cutting speed mainly determines the mechanism of chip formation. Results of tool-life testing indicate that thermal softening of tool point combined with abrasion is the predominant tool failure mechanism.

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Chip Formation in the Machining of Hardened Steel

Cited by 176 publications

References 13 publications

In situ analysis of flow dynamics and deformation fields in cutting and sliding of metals

In situ analysis of flow dynamics and deformation fields in cutting and sliding of metals

Critical cutting speed for onset of serrated chip flow in high speed machining

Machining aspects of a high carbon Fe3Al alloy

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