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Determination of the minimum chip thickness and the effect of the plowing depth on the residual stress field in micro-cutting of 18 Ni maraging steel

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Abstract

Due to the cutting-edge radius effect in micro-cutting, there exists some material sticking in front of the cutting-edge named stagnation zone, above which the material flows as chips. The location of the stagnation zone is reported to be associated with the minimum chip thickness in micro-cutting, which is a significant value influencing the cutting mechanics and the machined surface integrity in micro-cutting. The determination of the minimum chip thickness is of great importance in micro-cutting process. In this paper, the cutting force analysis on the shearing plane was carried out considering the ductile fracture and cutting-edge radius. Based on the cutting force analysis, this paper proposed a new method to determine the minimum chip thickness in micro-cutting of 18Ni maraging steel through finite element simulation. The minimum chip thickness was calculated to be 0.25 times the cutting-edge radius, which is in a good agreement with the velocity distribution analysis of the material around the cutting-edge. In addition, the effect of the plowing depth which was equivalent to the height of the stagnation zone on the residual stress filed was investigated using energy criterion. The energy stored in the machined surface increased with the plowing depth, resulting from the increasing thermal-mechanical load due to plowing.

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Funding

This work is supported by the National Natural Science Foundation of China (51675312, U1708256).

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Authors and Affiliations

  1. Center for Advanced Jet engineering Technologies (CaJET), Key Laboratory of High-efficiency and Clean Mechanical Manufacture (Ministry of Education), National Demonstration Center for Experimental Mechanical Engineering Education (Shandong University), School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Yang Yao, Hongtao Zhu, Chuanzhen Huang, Pu Zhang & Peng Yao

  2. School of Mechanical and Manufacturing Engineering, The University of New South Wales, Sydney, NSW, 2052, Australia

    Jun Wang

  3. Department of Computer Science and Software Engineering, Xi’an Jiaotong-Liverpool University, Suzhou, 215123, China

    Xiaodan Wang

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  1. Yang Yao
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  2. Hongtao Zhu
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  3. Chuanzhen Huang
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  4. Jun Wang
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  5. Pu Zhang
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  6. Peng Yao
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  7. Xiaodan Wang
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Correspondence to Hongtao Zhu or Chuanzhen Huang.

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Yao, Y., Zhu, H., Huang, C. et al. Determination of the minimum chip thickness and the effect of the plowing depth on the residual stress field in micro-cutting of 18 Ni maraging steel. Int J Adv Manuf Technol 106, 345–355 (2020). https://doi.org/10.1007/s00170-019-04439-x

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