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Study of segmented chip formation in cutting of high-strength lightweight alloys

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Abstract

Chip segmentation results in fluctuation of the cutting force, deteriorated tool wear and surface finish, thereby plays an important role in the machining process. Although extensive research has been carried out on studying the segmented chip formation, the mechanism of chip segmentation has remained under debate. This paper aims to investigate the mechanism by combining numerical and experimental methods. Finite element (FE) models of the orthogonal cutting process of A2024–T351 aluminum alloy and Ti6Al4V titanium alloy were developed with three numerical formulations: Lagrangian (LAG), arbitrary Lagrangian–Eulerian (ALE), and coupled Eulerian and Lagrangian (CEL). The appropriate model for predicting the segmented chip formation process was selected by systematic comparison. The mechanism of chip segmentation was thoroughly investigated by the selected numerical model. It revealed that the adiabatic shear band (ASB) is generated not only from the chip root but also from the free chip surface. The finding was then validated by observing the microstructure of chips from high-speed dry-cutting tests.

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The authors confirm that the data supporting the findings of this study are available within the article and its supplementary materials.

Abbreviations

A :

initial yield stress (MPa)

a p :

cutting depth (mm)

B :

hardening modulus (MPa)

C :

strain rate dependency coefficient

D :

damage variable

D 1, initial failure strain: D 2, exponential factor; D 3, triaxiality factor; D 4, strain rate factor; η, stress triaxiality; C p :

specific heat (J·kg−1·C−1)

E :

Young’s modulus (Gpa)

f :

feed rate (mm/rev.)

γ n, rake angle(deg); α n, clearance angle (deg); r n, cutting edge radius (μm); F c :

cutting force (N)

G f :

fracture energy (N/mm)

I :

tensile failure mode

II :

sliding (or shearing) failure mode

K c :

fracture toughness (MPa·m1/2)

m :

thermal softening coefficient

n :

work-hardening exponent

t c :

cutting time (μs)

λ :

thermal conductivity (W·m−1·C−1)

ρ :

density (kg/m3)

T m :

melting temperature (°C)

T 0 :

reference temperature (°C)

T :

instantaneous temperature (°C)

v c :

cutting speed (m/min)

\( {\overline{u}}_{\mathrm{f}} \) :

equivalent plastic displacement at failure (mm)

\( \overline{u} \) :

equivalent plastic displacement (mm)

\( \overline{\varepsilon} \) :

equivalent plastic strain

\( \dot{\overline{\varepsilon}} \) :

equivalent plastic strain rate (s−1)

\( {\dot{\varepsilon}}_0 \) :

reference strain rate (s−1)

\( {\overline{\varepsilon}}_{\mathrm{f}}^{\mathrm{pl}} \) :

equivalent plastic strain at failure

\( \Delta {\overline{\varepsilon}}^{\mathrm{pl}} \) :

increment of equivalent plastic strain

\( {\overline{\varepsilon}}_0^{\mathrm{pl}} \) :

equivalent plastic strain at damage initiation

\( \overline{\sigma} \) :

von Mises plastic equivalent stress (MPa)

σ y :

yield stress (MPa)

ω :

damage initiation criterion

ν :

Poisson’s ratio

τ f :

frictional shear stress (MPa)

τ max :

maximum shear stress while it relates to the normal stress (MPa)

σ n, normal stress (MPa); μ, coefficient of friction; r pl :

heat flux per unit volume due to plastic straining

κ :

inelastic heat fraction Taylor–Quinney coefficient

\( \dot{Q} \) :

rate of frictional energy dissipation

η h :

fraction of dissipated energy converted into heat

τ :

frictional stress (MPa)

\( \dot{\gamma} \) :

slip rate

f w :

weighting factor for the heat between the interacting surfaces

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Acknowledgments

We thank Sandvik for providing the tool inserts and Richard Overstreet for helping with the machining test.

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  1. Department of Mechanical Engineering, Clemson University, Clemson, SC, 29634, USA

    Chao Zhang & Hongseok Choi

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Zhang, C., Choi, H. Study of segmented chip formation in cutting of high-strength lightweight alloys. Int J Adv Manuf Technol 112, 2683–2703 (2021). https://doi.org/10.1007/s00170-020-06057-4

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