Influences of chip serration on micro-topography of machined surface in high-speed cutting

Su, Guosheng; Liu, Zhanqiang; Li, Liang; Wang, Qingqing

doi:10.1016/j.ijmachtools.2014.10.012

Cited by 65 publications

(23 citation statements)

References 14 publications

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“…That is to say, the surface integrity can be improved at higher cutting speed. The trend is in accordance with the available experimental results [42]. For a given cutting speed, Deborah number decreases with the increasing CEF.…”

Section: Characteristic Instability Time Within Sszsupporting

confidence: 92%

Enhancing surface integrity by high-speed extrusion machining

Liu

Cai

Shang

et al. 2016

Int J Adv Manuf Technol

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High-speed machining (HSM) is an advanced machining technology to form components. However, the poor surface integrity tends to appear due to chip flow instability in HSM. It is found that the surface integrity results from the competition of shear deformation instability between in primary shear zone (PSZ) and in separating shear zone (SSZ). To improve the surface integrity of machined components, the systematic high-speed extrusion machining (HSEM) experiments of magnesium alloy AZ31B with different constraint extrusion factors (CEFs) were carried out. The instability of shear deformation in PSZ is suppressed, and the microwaves on machined surface disappear when CEF is equal to or larger than a certain value. The measurements of the machined surface show that an improvement of surface integrity is achieved if CEF exceeds a certain value. The theoretical model for HSEM was established to elucidate the critical CEF. The underlying physics of surface integrity in HSEM is further revealed. The experimental results verify the validity of the theoretical model.

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Section: Characteristic Instability Time Within Sszsupporting

confidence: 92%

Enhancing surface integrity by high-speed extrusion machining

Liu

Cai

Shang

et al. 2016

Int J Adv Manuf Technol

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show abstract

“…During metal cutting, the machining conditions influence the cut chip morphology. The chip morphology in turn influences for example the cutting forces, tool wear, surface characteristics and chip breakage and removal [1,2]. At low cutting speeds the chips often show a continuous morphology, which changes to segmented chips at increased cutting speed [3].…”

Section: Introductionmentioning

confidence: 99%

Microstructural examination of shear localisation during high strain rate deformation of Alloy 718

Johansson

Persson

Lai

et al. 2016

Materials Science and Engineering: A

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Chip formation during metal cutting involves high strain rates and large deformations. Under many conditions, the deformation is concentrated in narrow bands due to shear localisation from adiabatic heating. In order to understand the localisation process, it is necessary to increase the knowledge regarding the microstructural evolution during deformation. However, the deformation that occurs during chip formation is hard to measure. Therefore, this study utilises top-hat specimens deformed at high strain rates in order to generate localised shear bands in the Ni-based superalloy Alloy 718, with defined measurable deformation. The resulting shear bands in the top-hat specimens are compared with those generated in metal cutting chips and studied in order to characterise the deformation occurring at a microstructural level. The resulting microstructures in the top-hat specimens and machining chips are found to be similar, with heavily localised deformation into narrow shear bands and homogeneously sheared microstructure adjacent to the bands. The centres of the shear bands are heavily deformed with ultra-fine grains, indicating dynamic recrystallisation during the deformation. The results indicate that the shear deformation produced by high strain rate testing of top-hat specimens can provide an excellent means of replicating the conditions for shear localisation during metal cutting. However, care should be taken to design the tests so that the local conditions are representative in terms of strains and strain rates.

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“…Schematic illustrations of the continuous cutting mechanism and SEM photographs of the chip formation are show in Fig.5 (a) and (c). The uniform material sliding in continuous cutting leaves uniform microwaves on the machined surface [13]. However, UPRFC has a different cutting mechanism whereby the intermittent rotary cutting mechanism makes the chip thickness inconsistent along its length direction in the chip formation process; that is, thinner (theoretically zero thickness) at two ends (tool entry and tool exit in Fig.5 (d)) and thicker at the middle, as is shown in Fig.5 (b) and (d).…”

Section: Resultsmentioning

confidence: 99%

“…However, very few studies have focused on material sliding behavior in chip formation and the related surface topography changes. The most comprehensive research into the relation between saw-tooth caused by material sliding and surface waves was conducted by Su et al (2015) [13]. In their study, the correlations between chip morphology and machined surface micro-topography at different chip serration stages encountered in high-speed cutting were explored.…”

Section: Introductionmentioning

confidence: 99%

Case study of surface micro-waves in ultra-precision raster fly cutting

Zhang

et al. 2016

Precision Engineering

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Influences of chip serration on micro-topography of machined surface in high-speed cutting

Cited by 65 publications

References 14 publications

Enhancing surface integrity by high-speed extrusion machining

Enhancing surface integrity by high-speed extrusion machining

Microstructural examination of shear localisation during high strain rate deformation of Alloy 718

Case study of surface micro-waves in ultra-precision raster fly cutting

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