Cutting AISI 1045 steel at very high speeds

Abstract

An experimental device, based on the light-gas gun technology, was set up to realize high speed cutting over a wide range of cutting speeds from 30 m/s to 200 m/s. High-speed cutting experiments were performed on AISI 1045 steels. The investigation of chip morphology, micro-structures, micro-hardness and the finished surface integrity were carried out, focusing on the physical phenomena accompanying the saw-tooth chip formation. The results reveal that, with increasing the cutting speed, the transition of chip morphology from continue to saw-tooth could be attributed to repeated thermoplastic shearbanding rather than periodic cracking. In particular, a severe material flow leading to mass transfer of heat was observed at very high cutting speed. The effect of mass transfer of heat on thermoplastic shear instability was further investigated, which implies that the mass transfer of heat would retard the formation of saw-tooth chip. Finally, the influence of cutting speed and mass transfer on the temperature distribution during high speed machining was briefly discussed.

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

“…3b-f). Clearly, the serrated (a) Schematic of the light gas gun testing setup for modeling the orthogonal cutting process of materials at high cutting speeds (Ye et al, 2012). The inset shows the schematic plot for the oblique cutting process; (b) the real photograph of the cutting platform of materials.…”

“…An uncoated P10 carbide tool was used in these machining processes. The details of the machining experiments can be found in Ye et al (2012).…”

Modelling of the Relationship of Adiabatic Shear and Cutting Conditions for Higher Cutting Speed Ranges

“…Therefore, it is extensively applied in the fields of aerospace, automotive and moulding, etc., and is widely used [1]. The main difference between high speed cutting and conventional cutting is that the serrated chip is often produced in high speed cutting [2] and [3], and the continuous chip is produced in conventional cutting. Fig.…”

“…On the basis of saturation limit model, the critical fracture energy was predicted by cutting conditions and compared with the experimental results. Ye et al [3] set up an experimental device, based on the light-gas gun technology, to realize high speed cutting over a wide range of cutting speed from 30 m/s to 200 m/s. Highspeed cutting experiments were performed on AISI 1045 steel.…”

Suppression of repeated adiabatic shear banding by dynamic large strain extrusion machining

“…In science, the serrated chip formation is originated from the repeated thermo-plastic shear banding within primary shear zone (PSZ) in HSM, which has been demonstrated in more and more works (Burns and Davies, 2002;Molinari et al, 2002Molinari et al, , 2013Recht, 1964Recht, , 1985Ye et al, 2012Ye et al, , 2013. The mechanism of multiple shear bands in HSM is different from that in simple shear because the materials convection exists in the former.…”