Skip to main content
SpringerLink
Log in

Adiabatic shear fracture prediction in high-speed cutting at various negative rake angles and feeds

  • Published:
Advances in Manufacturing Aims and scope Submit manuscript

Abstract

The critical characteristics of adiabatic shear fracture (ASF) that induce the formation of isolated segment chip in high-speed machining was further investigated. Based on the saturation limit theory, combining with the stress and deformation conditions and the modified Johnson-Cook constitutive relation, the theoretical prediction model of ASF was established. The predicted critical cutting speeds of ASF in high-speed machining of a hardened carbon steel and a stainless steel were verified through the chip morphology observations at various negative rake angles and feeds. The influences of the cutting parameters and thermal–mechanical variables on the occurrence of ASF were discussed. It was concluded that the critical cutting speed of ASF in the hardened carbon steel was higher than that in the stainless steel under a larger feed and a lower negative rake angle. The proposed prediction model of ASF could predict reasonable results in a wide cutting speed range, facilitating the engineering applications in high-speed cutting operations.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

Abbreviations

\(t\) :

Time (s)

\(v\) :

Cutting velocity (m·\({\text{s}}^{ - 1}\))

\(v_{\text{S}}\) :

Shear velocity (m·\({\text{s}}^{ - 1}\))

\(v\left( y \right)\) :

Velocity distribution (m·\({\text{s}}^{ - 1}\))

a :

Rate-related gradient factor

\(a_{\text{c}}\) :

Uncut thickness (m)

\(a_{\text{ch}}\) :

Chip thickness (m)

\(a_{\beta }\) :

Experimental coefficient

\(\phi\) :

Shear angle (\(^{ \circ }\))

\(\psi_{0}\) :

Section shrinkages (%)

\(\psi\) :

Angle between free surface plane and shear plane (\(^{ \circ }\))

\(p_{y}\) :

Momentum (kg·m/s)

\(U\) :

Upper side displacement of TP region (m)

\(W\) :

Boundary shear work of RP region (J·\({\text{m}}^{ - 2}\))

\(S\) :

Shear bandwidth (\(\upmu{\text{m}}\))

\(h_{\text{S}}\) :

Half thickness of primary shear zone (m)

\(\xi\) :

Location of thermo-plastic boundary (m)

\(\sigma\) :

Compressive stress (MPa)

\(\sigma_{\text{b}}\) :

Tensile strength (MPa)

\(\sigma_{\text{S}}\) :

Yield strength (MPa)

\(\delta\) :

Malleability (%)

\(\tau\) :

Shear stress (MPa)

\(\hat{\tau }\) :

Equivalent shear stress (MPa)

\(\tau_{\text{p}}\) :

Equivalent peak stress (MPa)

\(\tau \left( {\gamma ,\dot{\gamma },\theta } \right)\) :

Constitutive relation (MPa)

\(f_{1} \left( \varepsilon \right)\) :

Component of strain hardening effect

\(f_{2} \left( {\dot{\varepsilon }} \right)\) :

Component of strain rate hardening effect

\(f_{3} \left( {\theta^{*} } \right)\) :

Component of thermal softening effect

\(\varepsilon\) :

Strain

\(\dot{\varepsilon }\) :

Strain rate (\({\text{s}}^{ - 1}\))

\(\hat{\varepsilon }\) :

Effective strain

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

Effective strain rate (\({\text{s}}^{ - 1}\))

\(\gamma\) :

Shear strain

\(\dot{\gamma }\) :

Shear strain rate (\({\text{s}}^{ - 1}\))

\(\gamma_{0}\) :

Rake angle (\(^{ \circ }\))

\(\gamma_{\text{S}}\) :

Strain of RP region

\(L_{\text{P}}\) :

Teeth space (mm)

\(L_{\text{S}}\) :

Shear band space (mm)

\(\theta\) :

Temperature (K)

\(\theta_{0}\) :

Room temperature (K)

\(\theta_{\text{m}}\) :

Melt temperature (K)

\(\Delta \theta\) :

Temperature rise (K)

\(\rho\) :

Mass density (kg·\({\text{m}}^{ - 3}\))

\(c\) :

Thermal specific capacity (J·\({\text{kg}}^{ - 1}\)·\({\text{K}}^{ - 1}\))

\(\chi\) :

Thermal diffuse coefficient (m2·\({\text{s}}^{ - 1}\))

\(\beta\) :

Taylor and Quinney coefficient

\(\beta_{0}\) :

Incline angle of the free surface (\(^{ \circ }\))

\(G_{\text{ASB}}\) :

ASB energy (J·\({\text{m}}^{ - 2}\))

\(G_{\text{ASB}}^{\text{f}}\) :

Saturation limit (J·\({\text{m}}^{ - 2}\))

References

  1. Recht R (1964) Catastrophic thermoplastic shear. J Appl Mech 31:189–193

    Article  Google Scholar 

  2. Komanduri R, Schroeder T (1984) On shear instability in machining a nickel-iron base superalloy. High Speed Mach 108:287–307

    Google Scholar 

  3. Barry J, Byrne G (2002) The mechanisms of chip formation in machining hardened steels. J Manuf Sci Eng 124(3):528–535

    Article  Google Scholar 

  4. Gente A, Hoffmeister H, Evans C (2001) Chip formation in machining Ti6Al4V at extremely high cutting speeds. CIRP Ann-Manuf Techn 50(1):49–52

    Article  Google Scholar 

  5. Davies M, Chou Y, Evans C (1996) On chip morphology, tool wear and cutting mechanics in finish hard turning. CIRP Ann-Manuf Techn 45(1):77–82

    Article  Google Scholar 

  6. Shaw M, Vyas A (1998) The mechanism of chip formation with hard turning steel. CIRP Ann-Manuf Techn 47(1):77–82

    Article  Google Scholar 

  7. Elbestawi M, Srivastava A, El-Wardany T (1996) A model for chip formation during machining of hardened steel. CIRP Ann-Manuf Techn 45(1):71–76

    Article  Google Scholar 

  8. Su G, Liu Z (2010) An experimental study on influences of material brittleness on chip morphology. Int J Adv Manuf Technol 51(1–4):87–92

    Article  Google Scholar 

  9. Poulachon G, Moisan A (2000) Hard turning: chip formation mechanisms and metallurgical aspects. J Manuf Sci Eng 122:406

    Article  Google Scholar 

  10. Wang MJ, Duan CZ, Liu HB (2004) Experimental study on adiabatic shear behavior in chip formation during orthogonal cutting. China Mech Eng 15(18):1603–1606

    Google Scholar 

  11. Sowerby R, Chandrasekaran N (1989) A proposal for the onset of chip segmentation in machining. Mater Sci Eng, A 119:219–229

    Article  Google Scholar 

  12. Marusich T, Ortiz M (1995) Modelling and simulation of high-speed machining. Int J Numer Meth Eng 38(21):3675–3694

    Article  MATH  Google Scholar 

  13. Xie J, Bayoumi A, Zbib H (1996) A study on shear banding in chip formation of orthogonal machining. Int J Mach Tools Manuf 36(7):835–847

    Article  Google Scholar 

  14. Guo Y, Yen D (2004) A FEM study on mechanisms of discontinuous chip formation in hard machining. J Mater Process Tech 155:1350–1356

    Article  Google Scholar 

  15. Hua J, Shivpuri R (2004) Prediction of chip morphology and segmentation during the machining of titanium alloys. J Mater Process Tech 150(1–2):124–133

    Article  Google Scholar 

  16. Gu L, Wang M, Duan C (2013) On adiabatic shear localized fracture during serrated chip evolution in high speed machining of hardened AISI 1045 steel. Int J Mech Sci 75:288–298

    Article  Google Scholar 

  17. Gu L, Kang G, Chen H et al (2016) On adiabatic shear fracture in high-speed machining of martensitic precipitation-hardening stainless steel. J Mater Process Tech 234:208–216

    Article  Google Scholar 

  18. Medyanik SN, Liu WK, Li S (2007) On criteria for dynamic adiabatic shear band propagation. J Mech Phys Solids 55(7):1439–1461

    Article  MathSciNet  MATH  Google Scholar 

  19. Liao SC, Duffy J (1998) Adiabatic shear bands in a Ti-6Al-4V titanium alloy. J Mech Phys Solids 46(11):2201–2231

    Article  Google Scholar 

  20. Dodd B, Bai Y (1989) Width of adiabatic shear bands formed under combined stresses. Mater Sci Technol 5(6):557–559

    Article  Google Scholar 

  21. ÖZel T, Zeren E (2006) A methodology to determine work material flow stress and tool-chip interfacial friction properties by using analysis of machining. J Manuf Sci Eng 128:119–129

    Article  Google Scholar 

  22. Gu L, Wang M, Chen H et al (2016) Experimental study on the process of adiabatic shear fracture in isolated segment formation in high-speed machining of hardened steel. Int J Adv Manuf Technol 86(1):671–679

    Article  Google Scholar 

  23. Ye GG, Xue SF, Jiang MQ et al (2013) Modeling periodic adiabatic shear band evolution during high speed machining Ti-6Al-4V alloy. Int J Plast 40:39–55

    Article  Google Scholar 

  24. Molinari A, Musquar C, Sutter G (2002) Adiabatic shear banding in high speed machining of Ti6Al4V: experiments and modeling. Int J Plast 18(4):443–459

    Article  MATH  Google Scholar 

  25. Li GH (2009) Prediction of diabatic shear in high speed machining based on linear pertubation analysis. Dalian University of Technology, Dalian

    Google Scholar 

  26. Zhou M, Rosakis A, Ravichandran G (1996) Dynamically propagating shear bands in impact-loaded prenotched plates I. Experimental investigations of temperature signatures and propagation speed. J Mech Phys Solids 44(6):981–1006

    Article  Google Scholar 

  27. Murr L, Ramirez A, Gaytan S et al (2009) Microstructure evolution associated with adiabatic shear bands and shear band failure in ballistic plug formation in Ti-6Al-4V targets. Mater Sci Eng A 516(1–2):205–216

    Article  Google Scholar 

  28. Liu M, Guo Z, Fan C et al (2016) Modeling spontaneous shear bands evolution in thick-walled cylinders subjected to external high-strain-rate loading. Int J Solids Struct 97–98:336–354

    Article  Google Scholar 

  29. Rittel D, Wang Z, Merzer M (2006) Adiabatic shear failure and dynamic stored energy of cold work. Phys Rev Lett 96(7):75502

    Article  Google Scholar 

  30. Dolinski M, Merzer M, Rittel D (2015) Analytical formulation of a criterion for adiabatic shear failure. Int J Impact Eng 85:20–26

    Article  Google Scholar 

Download references

Acknowledgements

This work is supported by the National Natural Science Foundation of China (Grant Nos. 51601155 & 51175063). Thanks for the language support from Ms. Nan Cui. Thanks for the support from School of Mechanical Engineering from Dalian University of Technology.

Author information

Authors and Affiliations

  1. School of Mechanical Engineering & State-Key Laboratory of Traction Power, Southwest Jiaotong University, Chengdu, 610031, People’s Republic of China

    Li-Yao Gu

  2. Mould & Die Research Institute, School of Mechanical Engineering, Dalian University of Technology, Dalian, 116024, People’s Republic of China

    Min-Jie Wang

Authors
  1. Li-Yao Gu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Min-Jie Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Li-Yao Gu.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Gu, LY., Wang, MJ. Adiabatic shear fracture prediction in high-speed cutting at various negative rake angles and feeds. Adv. Manuf. 6, 41–51 (2018). https://doi.org/10.1007/s40436-018-0212-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40436-018-0212-2

Keywords

Search

Navigation