In metal cutting, a good understanding of both the elastic-plastic deformation and the mechanical behavior of the workpiece material in the primary shear band (PSB) is essential to optimize machining process and ensure product quality, particularly when machining hard-to-cut materials (such as Titanium alloys) with a low thermal conductivity that gives rise to thermal stress localization near the tool-chip interface. This article presents an extended digital image correlation (DIC) method to obtain the highly intensive and localized elastic-plastic strain and stress fields in the PSB during cutting, the reconstruction of which requires the deformation history of each material point and an appropriate material constitutive model. Unlike existing DIC methods that infer elastic strains from two sequential images, the extended DIC not only reconstructs the displacement field but more importantly also captures the elastoplastic evolution of the material during the dynamic orthogonal cutting process, from which the plastic strain/stress fields in the PSB are determined experimentally. The effectiveness of the extended DIC method was evaluated numerically and experimentally for orthogonal cutting of Ti-6Al-4V alloys.

中文翻译：

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基于主剪切带模型的数字图像相关重建正交切削中的位移，应变和应力场

在金属切削中，充分了解主剪切带（PSB）中工件材料的弹塑性变形和机械性能对于优化加工过程和确保产品质量至关重要，特别是在加工难切削的材料时（例如钛合金）具有低热导率，从而在工具-芯片界面附近产生热应力局部化。本文提出了一种扩展的数字图像相关（DIC）方法，以获取PSB切割过程中的高强度和局部弹塑性应变和应力场，其重建需要每个材料点的变形历史和适当的材料本构模型。与现有的DIC方法从两个连续图像推断出弹性应变不同，扩展的DIC不仅可以重建位移场，而且更重要的是还可以捕获动态正交切削过程中材料的弹塑性演变，从而通过实验确定PSB中的塑性应变/应力场。通过数值和实验评估了扩展DIC方法对Ti-6Al-4V合金的正交切削的有效性。