Analytical and experimental study of shear localization in chip formation in orthogonal machining

Critical cutting speed for onset of serrated chip flow in high speed machining

“…This model could give reasonable predictions of the critical speeds for the emergence of serrated chip flow in machining of AISI 4340 and 1045 steels, but the predicted critical speeds for titanium were much higher than the experimental findings reported by Recht [17]. Later, Xie et al [22,23] extended Semiatin and Rao's model to investigate the effect of cutting conditions on the onset of shear localization in metal cutting. In their work, the power law relation was used to describe the material plastic behavior, and Loewen and Shaw's model was applied to estimate the shear band temperature.…”

Analytical modeling of chip geometry and cutting forces in helical ball end milling of superalloy Inconel 718

“…Besides, it is also understood from the literature that chip formation in high speed machining of Inconel 718 involves formation of adiabatic shear bands [11] in chips, which consume majority of the energy required for the material deformation in machining. Further, the machining process involves ploughing forces too that consume a good portion of energy, which does not contribute to the cutting operation [13].…”

“…Strain rate [11] During the mechanism of chip formation, the location of maximum strain rate is assumed to contain within the shear band.…”

“…Evaluation of shear strength of work material knowing the shear angle and the work material characteristics as function of stress, strain and temperature using Johnson-Cook constitutive [10] material model. Evaluation of shear band spacing in the serrated chip based on Xie et al [11] model. The mean tool temperature in machining evaluated using Kronenberg's analysis [12] is considered as primary shear zone temperature for this analysis.…”

2D numeric simulation of serrated-chip formation in orthogonal cutting of AISI316H stainless steel

“…Work to date has shown that little work has been carried on the determination of the chip formation when machining AISI304 stainless steels. In a study carried out by J. Q. Xie et al 17 , the theory of shear banding was included in the analysis of chip formation and chip instability. They used analytic and experimental methods to study these characteristics.…”