Experimental Determination of Large Strain Localization in Cut Steel Chips
Metal cutting is a severe plastic deformation process
involving large strains, high strain rates, and high temperatures.
Conventional analysis of the chip formation process is based on bulk
material deformation disregarding the inhomogeneous nature of the
material microstructure. A series of orthogonal cutting tests of AISI
1045 and 1144 steel were conducted which yielded similar process
characteristics and chip formations. With similar shear angles and cut
chip thicknesses, shear strains for both chips were found to range
from 2.0 up to 2.8. The manganese-sulfide (MnS) precipitate in the
1144 steel has a very distinct and uniform shape which allows for
comparison before and after chip formation. From close observations
of MnS precipitates in the cut chips it is shown that the conventional
approach underestimates plastic strains in metal cutting.
Experimental findings revealed local shear strains around a value of
6. These findings and their implications are presented and discussed.
[1] M.C. Shaw, Metal cutting principles. Belmont, CA: Wadsworth, 1993,
pp. 123-135.
[2] H. Ernst. Physics of Metal Cutting. Cincinnati Milling Machine
Company, 1938.
[3] W.B. Rice. "The formation of continuous chips in metal cutting", in The
Engineering Journal, Engineering Institution of Canada, vol. 44, Feb.
1961, pp. 41-45.
[4] P. Albrecht. "New developments in the theory of the metal-cutting
process part 1: The ploughing process in metal cutting", in the Journal
of Engineering for Industry, vol. 348, Nov. 1960, pp. 348-358.
[5] P. Albrecht. "New development in the theory of the metal-cutting
process part 2: The theory of chip formation", in the ASME Journal of
Engineering for Industry, vol. 83, 1961, pp. 557-571.
[6] C.S. Sharma, W.B. Rice, and R. Salmon. "A relationship between chip
type and shear strain", in the Annals of the CIRP, vol. 19, 1971, pp.
545-549.
[7] R.F. Recht. "Catastrophic thermoplastic shear", in the ASME Journal of
Applied Mechanics, vol. 31, 1964, pp. 189-193.
[8] R.F. Recht, "A dynamic analysis of high-speed machining:, in the
ASME Journal of Engineering for Industry, 1985, 99. 309-315.
[9] H. Zhen-Bin and R. Komanduri, "On a thermo-mechanical model for
shear instability in machining", in the Annals of the CIRP, vol. 44:1,
1995, pp. 69-73.
[10] M.A. Davies, T.J. Burns, and C.J. Evans. "On the dynamics of chip
formation in machining hard metals", in the Annals of the CIRP, vol.
46, 1997, pp. 1-6.
[11] H.O. Gekonde, X. Zhang, J. Gao, S.V. Subramanian "Design of steels
for high speed machining", in Ironmaking and Steelmaking, vol. 26, no.
5, 1999, pp. 333-338.
[12] H.O. Gekonde, G. Zhu, X. Zhang, S.V. Subramanian, "Role of
microstructural softening events in metal cutting", in Machine Science
and Technology,vol.6, 2002, pp. 353-364.
[13] M.E. Merchant, "Mechanics of the metal cutting process I: Orthogonal
cutting and a type 2 chip", in the Journal of Applied Physics, vol. 16,
1945, pp. 267-275.
[14] M.E. Merchant, "Mechanics of the metal cutting process II: Plasticity
conditions in orthogonal cutting", Journal of Applied Physics, vol. 16,
1945, pp. 318-324.
[15] E.H. Lee and B.W. Shaffer, "The theory of plasticity applied to a
problem of machining", in the Journal of Applied Mechanics, vol 18,
1951, pp. 405-413.
[16] W.B. Palmer and P.L.B. Oxley. "Mechanics of orthogonal machining",
in the Proceedings of the Institution of Mechanical Engineers, vol. 173,
no. 4, 1959, pp. 623-638.
[17] P.L.B. Oxley and M.J.M. Welsh, "Calculating the shear angle in
orthogonal metal cutting from fundamental stress-strain-strain rate
properties of the workpiece material", in the Proceedings of the Fourth
International Conference on Machine Tool Design and Research, 1963,
pp. 73-86.
[18] P.L.B. Oxley and M.G. Stevenson, "Measuring stress/strain properties at
very high strain rates using a machining test", in the Journal of the
Institute of Metals, vol. 95, 1967, pp. 308-313.
[19] R.G. Fenton and P.L.B. Oxley, "Mechanics of orthogonal machining:
Allowing for the effects of strain rate and temperature on tool-chip
friction"-, in the Proceedings of the Institution of Mechanical
Engineers, vol. 183, no. 22, 1968, pp. 417-428.
[20] T.H.C. Childs and M.I. Mahdi, "On the stress distribution between the
chip and tool during metal turning", in the Annals of the CIRP, vol. 38,
1989, pp. 55-58.
[21] A. Simoneau, E., Ng, M.A. Elbestawi, "Chip Formation During
Microscale Cutting of a Medium Carbon Steel" in the International
Journal of Machine Tools and Manufacture, vol. 46, issue 5, 2006, pp.
467-481.
[22] A. Simoneau, E. Ng, M.A. Elbestawi, "The Effect of Microstructure on
Chip Formation and Surface Defects in Microscale, Mesoscale, and
Macroscale Cutting of Steel", in the Annals of the CIRP, vol. 55, 2006,
pp. 97-103.
[23] A. Simoneau, E. Ng, M.A. Elbestawi, "Grain Size and Orientation
Effects When Microcutting AISI 1045 Steel" in the Annals of the CIRP,
vol. 56, 2007, pp. 57-60.
[24] S.P.F.C. Jaspers and J.H. Dautzenberg, "Material behaviour in
conditions similar to metal cutting: Flow stress in the primary shear
zone", in the Journal of Materials Processing Technology, vol. 122,
2002, pp. 323-330.
[1] M.C. Shaw, Metal cutting principles. Belmont, CA: Wadsworth, 1993,
pp. 123-135.
[2] H. Ernst. Physics of Metal Cutting. Cincinnati Milling Machine
Company, 1938.
[3] W.B. Rice. "The formation of continuous chips in metal cutting", in The
Engineering Journal, Engineering Institution of Canada, vol. 44, Feb.
1961, pp. 41-45.
[4] P. Albrecht. "New developments in the theory of the metal-cutting
process part 1: The ploughing process in metal cutting", in the Journal
of Engineering for Industry, vol. 348, Nov. 1960, pp. 348-358.
[5] P. Albrecht. "New development in the theory of the metal-cutting
process part 2: The theory of chip formation", in the ASME Journal of
Engineering for Industry, vol. 83, 1961, pp. 557-571.
[6] C.S. Sharma, W.B. Rice, and R. Salmon. "A relationship between chip
type and shear strain", in the Annals of the CIRP, vol. 19, 1971, pp.
545-549.
[7] R.F. Recht. "Catastrophic thermoplastic shear", in the ASME Journal of
Applied Mechanics, vol. 31, 1964, pp. 189-193.
[8] R.F. Recht, "A dynamic analysis of high-speed machining:, in the
ASME Journal of Engineering for Industry, 1985, 99. 309-315.
[9] H. Zhen-Bin and R. Komanduri, "On a thermo-mechanical model for
shear instability in machining", in the Annals of the CIRP, vol. 44:1,
1995, pp. 69-73.
[10] M.A. Davies, T.J. Burns, and C.J. Evans. "On the dynamics of chip
formation in machining hard metals", in the Annals of the CIRP, vol.
46, 1997, pp. 1-6.
[11] H.O. Gekonde, X. Zhang, J. Gao, S.V. Subramanian "Design of steels
for high speed machining", in Ironmaking and Steelmaking, vol. 26, no.
5, 1999, pp. 333-338.
[12] H.O. Gekonde, G. Zhu, X. Zhang, S.V. Subramanian, "Role of
microstructural softening events in metal cutting", in Machine Science
and Technology,vol.6, 2002, pp. 353-364.
[13] M.E. Merchant, "Mechanics of the metal cutting process I: Orthogonal
cutting and a type 2 chip", in the Journal of Applied Physics, vol. 16,
1945, pp. 267-275.
[14] M.E. Merchant, "Mechanics of the metal cutting process II: Plasticity
conditions in orthogonal cutting", Journal of Applied Physics, vol. 16,
1945, pp. 318-324.
[15] E.H. Lee and B.W. Shaffer, "The theory of plasticity applied to a
problem of machining", in the Journal of Applied Mechanics, vol 18,
1951, pp. 405-413.
[16] W.B. Palmer and P.L.B. Oxley. "Mechanics of orthogonal machining",
in the Proceedings of the Institution of Mechanical Engineers, vol. 173,
no. 4, 1959, pp. 623-638.
[17] P.L.B. Oxley and M.J.M. Welsh, "Calculating the shear angle in
orthogonal metal cutting from fundamental stress-strain-strain rate
properties of the workpiece material", in the Proceedings of the Fourth
International Conference on Machine Tool Design and Research, 1963,
pp. 73-86.
[18] P.L.B. Oxley and M.G. Stevenson, "Measuring stress/strain properties at
very high strain rates using a machining test", in the Journal of the
Institute of Metals, vol. 95, 1967, pp. 308-313.
[19] R.G. Fenton and P.L.B. Oxley, "Mechanics of orthogonal machining:
Allowing for the effects of strain rate and temperature on tool-chip
friction"-, in the Proceedings of the Institution of Mechanical
Engineers, vol. 183, no. 22, 1968, pp. 417-428.
[20] T.H.C. Childs and M.I. Mahdi, "On the stress distribution between the
chip and tool during metal turning", in the Annals of the CIRP, vol. 38,
1989, pp. 55-58.
[21] A. Simoneau, E., Ng, M.A. Elbestawi, "Chip Formation During
Microscale Cutting of a Medium Carbon Steel" in the International
Journal of Machine Tools and Manufacture, vol. 46, issue 5, 2006, pp.
467-481.
[22] A. Simoneau, E. Ng, M.A. Elbestawi, "The Effect of Microstructure on
Chip Formation and Surface Defects in Microscale, Mesoscale, and
Macroscale Cutting of Steel", in the Annals of the CIRP, vol. 55, 2006,
pp. 97-103.
[23] A. Simoneau, E. Ng, M.A. Elbestawi, "Grain Size and Orientation
Effects When Microcutting AISI 1045 Steel" in the Annals of the CIRP,
vol. 56, 2007, pp. 57-60.
[24] S.P.F.C. Jaspers and J.H. Dautzenberg, "Material behaviour in
conditions similar to metal cutting: Flow stress in the primary shear
zone", in the Journal of Materials Processing Technology, vol. 122,
2002, pp. 323-330.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:60000", author = "A. Simoneau", title = "Experimental Determination of Large Strain Localization in Cut Steel Chips", abstract = "Metal cutting is a severe plastic deformation process
involving large strains, high strain rates, and high temperatures.
Conventional analysis of the chip formation process is based on bulk
material deformation disregarding the inhomogeneous nature of the
material microstructure. A series of orthogonal cutting tests of AISI
1045 and 1144 steel were conducted which yielded similar process
characteristics and chip formations. With similar shear angles and cut
chip thicknesses, shear strains for both chips were found to range
from 2.0 up to 2.8. The manganese-sulfide (MnS) precipitate in the
1144 steel has a very distinct and uniform shape which allows for
comparison before and after chip formation. From close observations
of MnS precipitates in the cut chips it is shown that the conventional
approach underestimates plastic strains in metal cutting.
Experimental findings revealed local shear strains around a value of
6. These findings and their implications are presented and discussed.", keywords = "Machining, metal cutting, microstructure, plastic strains, local strain.", volume = "7", number = "6", pages = "1205-6", }
