Abstract
High strain rate can be produced in many manufacturing processes, such as ultra-high-speed machining and ultra-precision machining. This paper reviews the high strain rate generated in different machining processes. Molecular dynamics (MD) and finite element (FE) for studying the mechanism and characteristics in manufacturing processes are analyzed; the ductile–brittle transition (DBT) and brittle-ductile transition (BDT) under high strain rate are also reviewed. And the machining characteristics in ultra-high-speed cutting and ultra-precision cutting are analyzed and compared, including cutting force, cutting heat, machined surface quality, tool wear, and chip formation. It is proposed that the DBT under high strain rate in ultra-high-speed machining is contradictory with the BDT in ultra-precision machining, because the reasons for producing a high strain rate are different. By increasing the cutting speed vc in ultra-precision cutting appropriately, the machinability of softer materials may be increased, and surface and subsurface damage can be reduced.
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Abbreviations
- v c :
-
Cutting speed or grinding speed
- a p :
-
Depth of cut or grinding depth
- f :
-
Feed rate
- ε(t) :
-
Strain
- \(\dot{\varepsilon }\) (t) :
-
Strain rate
- σ(t) :
-
Stress
- \({\varepsilon }_{R}\) :
-
Pulse strain amplitudes of the reflected waves
- \({\varepsilon }_{T}\) :
-
Pulse strain amplitudes of the transmitted waves
- A s :
-
Cross-sectional area of the specimen
- L :
-
Length of the specimen
- A 0 :
-
Cross-sectional area of the incident bar
- E :
-
Young’s modulus of the specimen
- C 0 :
-
Velocity of the elastic wave in the incident bar
- \(\tilde{\sigma }\) :
-
Equivalent flow stress
- \({\overline{\varepsilon }}_{n}\) :
-
Equivalent plastic strain
- \(\dot{\overline{\varepsilon }}\) :
-
Equivalent strain rate
- \({\overline{\varepsilon }}_{0}\) :
-
Reference strain rate
- T :
-
Current material temperature
- T m :
-
Material melting temperature
- T r :
-
Room temperature
- A :
-
Initial yield strength
- B :
-
Strain hardening modulus
- N :
-
Strain hardening index
- C :
-
Strain rate hardening index
- m :
-
Heat softening index
- φ :
-
Shear angle
- γ 0 :
-
Rake angle
- C 1 :
-
Cutting layer parameter
- v p :
-
Plastic wave propagation speed
- K I :
-
Stress intensity
- K C :
-
Fracture toughness
- Ra:
-
Surface roughness
- BDT:
-
Brittle-ductile transition
- DBT:
-
Ductile-brittle transition
- DRM:
-
Ductile removal mode
- SPHB:
-
Split Hopkinson pressure Bar
- JC:
-
Johnson–Cook
- MD:
-
Molecular dynamics
- FE:
-
Finite element
- FEM:
-
Finite element model
- FEA:
-
Finite element analysis
- MJC:
-
Modified Johnson–Cook constitutive model
- CPFE:
-
Crystal plasticity finite element model
- DDD:
-
Discrete dislocation dynamics
- DD:
-
Physical fundamental phenomenological dislocation dynamics
- SPDT:
-
Single-point diamond turning
- FCC:
-
Face-centered cubic
- SEM:
-
Scanning electron microscopy
- TEM:
-
Transmission electron microscopy
- TDUC:
-
Dry ultra-precision cutting technology
- UEVC:
-
Ultrasonic elliptical vibration-assisted cutting technology
- UDUC:
-
Dry ultra-precision cutting combined with ultrasonic elliptical vibration-assisted cutting technology
- SCD:
-
Single-crystal diamond
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This work was supported by the National Natural Science Foundation of China (Grant Nos. 52075302, 51875321).
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Xufeng Sun: investigation, methodology, writing–original draft. Peng Yao: writing–review and editing, supervision, project administration, resources, conceptualization. Shuoshuo Qu: writing–review and editing. Xianpeng Zhang: validation. Shimeng Yu: validation. Wei Wang: writing–review and editing. Chuanzhen Huang: writing–review and editing. Dongkai Chu: writing–review and editing.
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Sun, X., Yao, P., Qu, S. et al. Material properties and machining characteristics under high strain rate in ultra-precision and ultra-high-speed machining process: a review. Int J Adv Manuf Technol 120, 7011–7042 (2022). https://doi.org/10.1007/s00170-022-09111-5
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DOI: https://doi.org/10.1007/s00170-022-09111-5