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The plastic flow stability of chip materials in metal cutting process
Ma W(马维)1; Shuang F(双飞)1,2
Corresponding AuthorMa, Wei(
AbstractThis study investigates the chip formation mechanism and relevant plastic flow stability in the orthogonal cutting process (OCP) through high-speed cutting experiments and theoretical modelling for four types of metals. The chip morphology transitions from continuous to serrated and to continuous again are observed with critical speeds depending on the work material properties and cutting conditions. To exam the influence of two-dimensional (2D) effects on plastic flow stability, a complete theoretical framework under plane strain state is established to model the 2D orthogonal cutting process. Based on the new framework, a set of governing equations with three dimensionless parameters are used to analytically derive a universal instability criterion, the approximate velocity fields, and stress fields in the expanding chip formation zone (CFZ). It is shown that the plastic flow of continuous chip may become unstable once the cutting speed reaches a critical value. In contrast to the shear localization deformation in the serrated chip, we found a new instability mechanism occurring in the continuous chip which undergoes the uniform but severe shear deformation due to the plane strain loadings. A new dimensionless parameter therefore is proposed to describe the plastic instability in continuous chip and the shear banding instability in serrated chip. The difference of two instability modes is further investigated in terms of dissipation mechanism of cutting energy, and the plastic instability of continuous chip is shown as the best instability mode regarding tool vibration and surface machining quality. These findings provide practical insights into improving modern cutting technology by controlling the plastic flow instability.
KeywordMetal cutting Plastic flow stability Instability criterion Dimensional analysis Transition of chip morphology Cutting energy
Indexed BySCI ; EI
WOS IDWOS:000498491100007
WOS Research AreaAutomation & Control Systems ; Engineering
WOS SubjectAutomation & Control Systems ; Engineering, Manufacturing
Funding ProjectNational Nature Science Foundation of China[11572337] ; National Nature Science Foundation of China[11772346] ; National Nature Science Foundation of China[51575029]
Funding OrganizationNational Nature Science Foundation of China
ContributorMa, Wei
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Document Type期刊论文
Affiliation1.Chinese Acad Sci, Inst Mech, Beijing 100190, Peoples R China;
2.Univ Florida, Dept Mech & Aerosp Engn, Gainesville, FL 32611 USA
Recommended Citation
GB/T 7714
Ma W,Shuang F. The plastic flow stability of chip materials in metal cutting process[J]. INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY,2019,105(5-6):1933-1948.
APA 马维,&双飞.(2019).The plastic flow stability of chip materials in metal cutting process.INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY,105(5-6),1933-1948.
MLA 马维,et al."The plastic flow stability of chip materials in metal cutting process".INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 105.5-6(2019):1933-1948.
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