The plastic flow stability of chip materials in metal cutting process

doi:10.1007/s00170-019-04353-2

IMECH-IR > 流固耦合系统力学重点实验室

	The plastic flow stability of chip materials in metal cutting process
	Ma W(马维)1 ; Shuang F(双飞)1,2
通讯作者	Ma, Wei(watwm@imech.ac.cn)
发表期刊	INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
	2019-12-01
卷号	105 期号:5-6 页码:1933-1948
ISSN	0268-3768
摘要	This 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.
关键词	Metal cutting Plastic flow stability Instability criterion Dimensional analysis Transition of chip morphology Cutting energy
DOI	10.1007/s00170-019-04353-2
收录类别	SCI ; EI
语种	英语
WOS记录号	WOS:000498491100007
关键词[WOS]	FORMATION MECHANISMS ; MODEL ; INSTABILITY ; TITANIUM ; SPEED ; TOOL
WOS研究方向	Automation & Control Systems ; Engineering
WOS类目	Automation & Control Systems ; Engineering, Manufacturing
资助项目	National Nature Science Foundation of China[11572337] ; National Nature Science Foundation of China[11772346] ; National Nature Science Foundation of China[51575029]
项目资助者	National Nature Science Foundation of China
论文分区	二类
力学所作者排名	1
RpAuthor	Ma, Wei
引用统计	被引频次：1[WOS] [WOS记录] [WOS相关记录]
文献类型	期刊论文
条目标识符	http://dspace.imech.ac.cn/handle/311007/81265
专题	流固耦合系统力学重点实验室
作者单位	1.Chinese Acad Sci, Inst Mech, Beijing 100190, Peoples R China; 2.Univ Florida, Dept Mech & Aerosp Engn, Gainesville, FL 32611 USA
推荐引用方式 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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