Controlling segmentation in cutting of metals

We examine segmented chip formation and associated flow dynamics in cutting of metals of low-to-moderate workability using high-speed imaging. Segmentation is initiated by a surface instability – formation of a ductile crack in a prow – on workpiece surface ahead of the tool, this crack then propaga...

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Bibliographic Details
Published in:CIRP annals 2019, Vol.68 (1), p.41-44
Main Authors: Saei, Mojib, Udupa, Anirudh, Viswanathan, Koushik, Sugihara, Tatsuya, M’Saoubi, Rachid, Chandrasekar, Srinivasan
Format: Article
Language:English
Subjects:
Fracture analysis
High-speed imaging
Machining
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Summary:We examine segmented chip formation and associated flow dynamics in cutting of metals of low-to-moderate workability using high-speed imaging. Segmentation is initiated by a surface instability – formation of a ductile crack in a prow – on workpiece surface ahead of the tool, this crack then propagates towards the tool tip. Prow-crack initiation occurs at a critical strain ˜0.75 that is independent of material and deformation geometry. This ductile failure is analyzed in terms of local hydrostatic stress state and stress triaxiality. Material-agnostic methods to suppress and enhance segmentation using constrained cutting and a mechanochemical effect are demonstrated.
ISSN:0007-8506
DOI:10.1016/j.cirp.2019.04.073