Prediction of critical cutting condition for onset of serrated chip in ductile metallic material using dynamic yield stress. (April 2021)

• Record Type: Journal Article
• Authors: Liang, Liang; Lin, Guozhi; Tan, Huanheng; Yuan, Jiandong; He, Lin; Jiang, Changcheng; Li, Xiaoqiang
• Is Part Of: Journal of manufacturing processes. Volume 64(2021)
• Page Start: 927
• Page End: 936
• Publication Date: 2021-04
• Subjects: Dynamic yield stress -- Critical cutting condition -- Serrated chip -- Slot milling -- Cutting force; Production management -- Data processing -- Periodicals; Manufacturing processes -- Periodicals; Procestechnologie; Productietechniek; Production -- Gestion -- Informatique -- Périodiques; Fabrication -- Périodiques; Manufacturing processes; Production management -- Data processing; Periodicals; 670.5
• DOI: 10.1016/j.jmapro.2021.02.046
• Languages: English
• ISSNs: 1526-6125

Abstract

Graphical abstract: Highlights: The critical cutting condition for the onset of serrated chip in ductile metallic material is determine based on the adiabatic shear theory and William's cutting model. The variation of the dynamic yield stress with the increase of cutting speed, which was determined by an improved Williams' model, was utilized as the criterion. A slot milling test is designed to obtain the variation of cutting force with respect to different undeformed chip thicknesses. The feasibility and effectiveness of the proposed model are verified by the experiments on ductile metal materials with low strength (silicon brass) or high strength (Ti6Al4V). Abstract: Anticipation of the critical cutting condition for the transition of continuous chip to serrated chip is a fundamental task in machining of ductile metallic material. In this study, the variation of the dynamic yield stress with the increase of cutting speed was utilized as the criterion to predict the critical cutting condition for onset of the serrated chip. In order to accurately and conveniently determine the value of dynamic yielding strength of the workpiece material during the cutting process, an improved Williams' model in conjunction with a 2D orthogonal slot milling test is proposed. Two typical ductile metals of silicon brass and Ti6Al4V were used as the workpiece material in this framework. Also, the chip morphology obtained in cylindrical turning test was used to validate the predicted results. For the two workpiece materials tested, it is observed that the error between the predicted result and the experimental result is always lower than 12%. The proposed methodology in this work exhibits its superiority in terms of calculation and predicting efficiency, which is still a challenge for traditional analytical method and finite element method.