Deformation of Serrated Chips Based on Minimum Energy Consumed for High Speed Machining

Abstract

The geometrical model for serrated chip was set up by studying the characteristic of typical chip during high speed machining. According to the adiabatic shear theory under the condition of high speed machining, friction force and flow velocity on back surface of chip as well as shear force and shear velocity on sliding plane were obtained by establishing mechanics and kinetic models via analyzing equilibrium forces exerted on the saw-tooth chip at the moment when the catastrophic thermoplastic instability occurred on slippage plane, then energy equation for cutting was offered. With strain, strain ratio, cutting temperature and deformation hardening considered, deformation equation was found using the principle of minimum energy. Finally, deformation equation and factors that affect deformation during high speed cutting were ascertained by combining analysis of deformation curve with cutting theory.

Research on Deformation Behaviors and Surface Quality Model at High-speed Cutting

“…The real high temperature and adiabatic shear of deformation zones caused by quick cutting lead to the material softening, and further result in notable changes in high-speed cutting mechanisms, and significantly affect the cutting performance. Meanwhile, the cutting chips with fast flowing speeds take away most of the cutting heat during the high-speed cutting [7][8][9][10], and notably decrease the temperature of the secondary deformation zone, which is available to improve the lifespan of the cutting tools. The quality model of high-speed cutting is a key to theoretically research of high-speed cutting technology [11][12][13][14][15], and provides important significance for the prediction of cutting quality and determination of cutting parameters.…”