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

A Review on the Adiabatic Shear Banding Mechanism in Metals and Alloys Considering Microstructural Characteristics, Morphology and Fracture

“…In addition, several manufacturing process tests have been implemented in order to investigate their effects on the propensity to form an ASB, such as forging [18,[20][21][22]194], extrusion [195] and rolling [23][24][25]196] in bulk forming, blanking/punching and deep drawing tests for sheet forming [25][26][27], high-speed machining [28][29][30][31][32][33][197][198][199][200] regarding cutting processes and projectile penetration via ballistic impact tests [34][35][36][37][38][39][40][41]. Figure 33a illustrates X-type and S-type ASB observations in Inconel 718 hot forging [21], while deformed and transformed ASBs are captured inside the serrated chip structure as the cutting speed increases in the high-speed machining of AISI 1045 steel, as shown in Figure 33b [30].…”

“…Also, serrated chip formation has been attributed to microcracking inside the ASB, where micro-voiding initially occurs and expands through an ellipsoid shape, reacting to the coalescence mechanism and micro-cracking genesis [31]. In addition, orthogonal cutting tests revealed that high cutting speeds and depths, together with the low rake angle of the tool, facilitate adiabatic shearing, bringing serrated chip deformation in AISI 1045 steel [32] and transforming ASBs with a saw-tooth chip in the Ti-6Al-4V alloy [33] where a further increase in feed reacts to wider shear bands.…”