Paper Title:

Deformation Mechanics Associated with Formation of Ultra-Fine Grained Chips in Machining

Periodical Materials Science Forum (Volumes 503 - 504)
Main Theme Nanomaterials by Severe Plastic Deformation
Edited by Zenji Horita
Pages 379-384
DOI 10.4028/www.scientific.net/MSF.503-504.379
Citation Michael Sevier et al., 2006, Materials Science Forum, 503-504, 379
Online since January 2006
Authors Michael Sevier, Seongeyl Lee, M. Ravi Shankar, Henry T.Y. Yang, Srinivasan Chandrasekar, W. Dale Compton
Keywords Finite Element (FE), Large Strain Deformation, Machining, Ultrafine Grained Material
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The deformation field associated with chip formation in plane strain (2-D) machining has been simulated using the finite element method (FEM), with the objective of developing 2-D machining as an experimental technique for studying very large strain deformation phenomena. The principal machining parameters are the tool rake angle, cutting velocity and the friction at the toolchip interface while the deformation field parameters are strain, strain rate and temperature. The relation between rake angle and the shear strain in the deformation zone is studied for the low-speed cutting of lead. This correspondence is validated by comparison with measurements of the deformation parameters made by applying a Particle Image Velocimetry (PIV) technique to highspeed photographic image sequences of the deformation. It is shown that plastic strains in the range of 1-15 can be realized in a controlled manner by appropriate choice of the rake angle. The unique capabilities offered by 2-D machining for studying micro- and nano- mechanics of large strain deformation, and the creation of ultra-fine grained materials are highlighted in the context of these results.