In this paper, the investigation of chip formation of aluminum alloy in different machining strategies (i.e., micro and macro cutting) is performed to develop a holistic view of the chip formation phenomenon. The study of chip morphology is useful to understand the mechanics of surface generation in machining. Experiments were carried out to evaluate the feed rate response (FRR) in both ultra-precision micro and conventional macro machining processes. A comprehensive study was carried out to explore the material removal mechanics with both experimental findings and theoretical insights. The results of the variation of chip morphology showed the dependence on feed rate in orthogonal turning. The transformation of discontinuous to continuous chip production—a remarkable phenomenon in micro machining—has been identified for the conventional macro machining of Al alloy. This is validated by the surface crevice formation in the transition region. Variation of the surface morphology confirms the phenomenology (transformation mechanics) of chip formation.

中文翻译：

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进给速率响应（FRR）对铝合金微细加工中切屑形成的影响

在本文中，对铝合金在不同加工策略（例如，微观和宏观切削）中切屑形成的研究进行了研究，以全面了解切屑形成现象。切屑形态的研究对于理解加工中表面生成的机理很有帮助。进行了实验，以评估超精密微加工和常规宏观加工工艺中的进给速度响应（FRR）。进行了全面的研究，以探索具有实验发现和理论见解的材料去除机理。切屑形态变化的结果表明，正交车削对进给速度有依赖性。从铝合金的常规宏观加工中可以发现，从不连续的切屑生产向连续的切屑生产的转变是微观加工中的显着现象。通过过渡区域中表面裂缝的形成可以证实这一点。表面形态的变化证实了切屑形成的现象学（转变力学）。