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

doi:10.1007/s40436-018-0212-2

Advances in Manufacturing ›› 2018, Vol. 6 ›› Issue (1): 41-51.doi: 10.1007/s40436-018-0212-2

• Articles • Previous Articles Next Articles

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

Li-Yao Gu¹, Min-Jie Wang²

1 School of Mechanical Engineering & State-Key Laboratory of Traction Power, Southwest Jiaotong University, Chengdu 610031, People's Republic of China;
2 Mould & Die Research Institute, School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, People's Republic of China

Received:2017-07-13 Revised:2018-01-08 Online:2018-03-25 Published:2018-03-25
Contact: Li-Yao Gu,guliyao0922@163.com E-mail:guliyao0922@163.com
Supported by:
This work is supported by the National Natural Science Foundation of China (Grant Nos. 51601155 & 51175063).

Abstract

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.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0212-2

Key words: Stress wave, Saturation limit, Fracture, Isolated segment, Prediction

Li-Yao Gu, Min-Jie Wang. Adiabatic shear fracture prediction in high-speed cutting at various negative rake angles and feeds[J]. Advances in Manufacturing, 2018, 6(1): 41-51.

TrendMD

References

1. Recht R (1964) Catastrophic thermoplastic shear. J Appl Mech 31:189-193
2. Komanduri R, Schroeder T (1984) On shear instability in machining a nickel-iron base superalloy. High Speed Mach 108:287-307
3. Barry J, Byrne G (2002) The mechanisms of chip formation in machining hardened steels. J Manuf Sci Eng 124(3):528-535
4. Gente A, Hoffmeister H, Evans C (2001) Chip formation in machining Ti6Al4V at extremely high cutting speeds. CIRP AnnManuf Techn 50(1):49-52
5. Davies M, Chou Y, Evans C (1996) On chip morphology, tool wear and cutting mechanics in finish hard turning. CIRP AnnManuf Techn 45(1):77-82
6. Shaw M, Vyas A (1998) The mechanism of chip formation with hard turning steel. CIRP Ann-Manuf Techn 47(1):77-82
7. Elbestawi M, Srivastava A, El-Wardany T (1996) A model for chip formation during machining of hardened steel. CIRP AnnManuf Techn 45(1):71-76
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
9. Poulachon G, Moisan A (2000) Hard turning:chip formation mechanisms and metallurgical aspects. J Manuf Sci Eng 122:406
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
11. Sowerby R, Chandrasekaran N (1989) A proposal for the onset of chip segmentation in machining. Mater Sci Eng, A 119:219-229
12. Marusich T, Ortiz M (1995) Modelling and simulation of highspeed machining. Int J Numer Meth Eng 38(21):3675-3694
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
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
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
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
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
18. Medyanik SN, Liu WK, Li S (2007) On criteria for dynamic adiabatic shear band propagation. J Mech Phys Solids 55(7):1439-1461
19. Liao SC, Duffy J (1998) Adiabatic shear bands in a Ti-6Al-4V titanium alloy. J Mech Phys Solids 46(11):2201-2231
20. Dodd B, Bai Y (1989) Width of adiabatic shear bands formed under combined stresses. Mater Sci Technol 5(6):557-559
21. Ö Zel 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
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
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
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
25. Li GH (2009) Prediction of diabatic shear in high speed machining based on linear pertubation analysis. Dalian University of Technology, Dalian
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
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
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
29. Rittel D, Wang Z, Merzer M (2006) Adiabatic shear failure and dynamic stored energy of cold work. Phys Rev Lett 96(7):75502
30. Dolinski M, Merzer M, Rittel D (2015) Analytical formulation of a criterion for adiabatic shear failure. Int J Impact Eng 85:20-26

[1]	M. Kimura, S. Iwamoto, M. Kusaka, K. Kaizu, Y. Nakatani, M. Takahashi. Effect of weld faying part groove shape on reduction of inner flash in steel pipe joints fabricated by friction welding [J]. Advances in Manufacturing, 2019, 7(4): 411-422.
[2]	Tian-Feng Zhou, Ben-Shuai Ruan, Jia Zhou, Xiao-Bin Dong, Zhi-Qiang Liang, Xi-Bin Wang. Mechanism of brittle fracture in diamond turning of microlens array on polymethyl methacrylate [J]. Advances in Manufacturing, 2019, 7(2): 228-237.
[3]	A. Pramanik, L. C. Zhang. Particle fracture and debonding during orthogonal machining of metal matrix composites [J]. Advances in Manufacturing, 2017, 5(1): 77-82.
[4]	A. Ducato, G. Buffa, L. Fratini, R. Shivpuri. Dual phase titanium alloy hot forging process design: experiments and numerical modeling [J]. Advances in Manufacturing, 2015, 3(4): 269-281.

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

PDF

Knowledge

Abstract

Cite this article

share this article

References

Related Articles 4

Recommended Articles

Metrics

Comments