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Twinned-serrated chip formation with minor shear bands in ultra-precision micro-cutting of bulk metallic glass

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Abstract

Bulk metallic glasses (BMGs) have unique properties due to their amorphous atomic structure such as excellent mechanical and thermal performances; BMGs are considered to be promising materials for many engineering applications. However, it is important to investigate the cutting mechanisms of BMG in ultra-precision micro-cutting (UPMC). This study focuses on experimental and theoretical investigations on the chip formation in UPMC of BMG. It was firstly found that twinned-serrated chips (TSCs) are generated in UPMC of BMG. The intrinsic cause is that BMG exhibits significant adiabatic effect, which was confirmed by a proposed finite element model. A series of ultra-precision micro-cutting tests have been carried out to verify the results of simulation and reveal the effect of rake angle on the cutting process of BMG. The simulation and experiment of chip formation proved that the adiabatic effect is the key factor to generate the serrated chips in the UPMC of BMG. In addition, there existed twinned shear in one cyclic of each serrated chip. The comparison between simulation and experiment under the machining condition of different tool rake angles showed that the serrated chip and cutting force are sensitive to the rake angle of tool.

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Authors and Affiliations

  1. State Key Laboratory of Ultraprecision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong, People’s Republic of China

    Sau Yee Chau & Suet To

  2. State Key Laboratory of Precision Electronic Manufacturing Technology and Equipment, Guangdong University of Technology, Guangzhou, China

    Zhanwen Sun

  3. College of Mechanical and Energy Engineering, Ningbo Institute of Technology, Zhejiang University, Ningbo, People’s Republic of China

    Hongbing Wu

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  1. Sau Yee Chau
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  2. Suet To
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  3. Zhanwen Sun
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  4. Hongbing Wu
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Correspondence to Suet To.

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Chau, S.Y., To, S., Sun, Z. et al. Twinned-serrated chip formation with minor shear bands in ultra-precision micro-cutting of bulk metallic glass. Int J Adv Manuf Technol 107, 4437–4448 (2020). https://doi.org/10.1007/s00170-020-04977-9

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  • DOI: https://doi.org/10.1007/s00170-020-04977-9

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