Cutting Depth Dictates the Transition from Continuous to Segmented Chip Formation,Physical Review Letters

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Cutting Depth Dictates the Transition from Continuous to Segmented Chip Formation
Physical Review Letters ( IF 8.1 ) Pub Date : 2021-12-03 , DOI: 10.1103/physrevlett.127.235502
Ramin Aghababaei _{1,

2} , Mohammad Malekan _{1,

3} , Michal Budzik _{1,

2}

Affiliation

The process of material cutting emerges from a series of nonlinear phenomena including frictional contact, plastic deformation, and fracture. While cutting dominated by shear deformation is of interest to achieve a smooth material removal and a high-quality surface finish, the fracture-induced chip breaking is of equal importance to prevent the formation of long chips. Here we show that discrepant observations and predictions of these two distinct cutting mechanisms can be reconciled into a unified framework. A simple analytical model is developed to predict the mechanism of chip formation in a homogeneous medium as a function of work piece intrinsic material properties, tool geometry, and the process parameters. The model reveals the existence of a critical depth of cut, below which the chip formation is gradually progressed by plastic deformation in the shear plane, and above which chips break off by abrupt crack propagation. The models’ prediction is validated by systematic in situ orthogonal cutting experiments and literature data for a wide range of materials over multiple length scales.

中文翻译：

切削深度决定了从连续切屑形成到分段切屑形成的转变

材料切割过程产生于一系列非线性现象，包括摩擦接触、塑性变形和断裂。虽然以剪切变形为主的切削对于实现平滑的材料去除和高质量的表面光洁度很重要，但断裂引起的断屑对于防止长切屑的形成也同样重要。在这里，我们表明可以将这两种不同切割机制的差异观察和预测整合到一个统一的框架中。开发了一个简单的分析模型来预测在均质介质中切屑形成的机制，作为工件固有材料特性、刀具几何形状和工艺参数的函数。该模型揭示了临界切深的存在，低于此值时，切屑通过剪切平面中的塑性变形逐渐形成，高于此值时，切屑会因裂纹的突然扩展而断裂。模型的预测得到了系统验证原位正交切割实验和文献数据，适用于多种长度范围内的各种材料。

更新日期：2021-12-04

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