Papers by Author: Min Jie Wang

Abstract: The formation and development of adiabatic shear localization in serrated chips have great significance to study of mechanism of high speed cutting. This paper investigates the theory prediction and experimental verification of the critical cutting speed of adiabatic shear localization, distribution of adiabatic shear band in serrated chip and the geometry of adiabatic shear band during high speed cutting of hardened steel. The results indicated that the theoretical prediction of critical cutting speed is consistent with the experimental results.With the increase of cutting speed, the width and spacing of adiabatic shear bands in the serrated chips decrease linearly. There are two types of adiabatic shear bands during the formation and development of adiabatic shear localization, i.e. the deformation shear band and the transformed shear band.

Abstract: To study the microstructure of white band is helpful for revealing formation mechanism of serrated chip. This paper investigates the microstructural characteristics of white band_s at primary and second deformation zone within the serrated chips produced during High Speed Machining (HSM) of AISI 1045 hardened steel usingoptical microscope, SEM, TEM, and electron microprobe, X-Ray diffraction. It was found that the white bands within primary and second deformation zone consist of small equiaxed grains which formed due to dynamic recrystallization during adiabatic shear, however, martensitic transformation just only taken place within the white band in second deformation zone. The re-distribution of chemical elements between the composition phases occurred due to the combined effect of adiabatic temperature rise and high speed deformation in formation process of white band. The former is result from adiabatic shear in primary deformation zone during formation of chip, while the latter is caused by the intense shear and friction between tool and chip.

Abstract: The component distribution of adiabatic shear banding during high speed cutting(HSC) is important to understand the phase transformation during formation of adiabatic shear band and mechanism of serrated chip formation. This paper analyzed element distribution inside and near the adiabatic shear bands formed during HSC of 30CrNi3MoV high strength steel using electronic probe. It was found that there is no obvious element segregation, but carbon element tends to gather towards adiabatic shear band’s boundaries. The density of carbon inside the shear bands tends to increase with the increase of cutting speed. The results indicated that the diffusion and gather of carbon may occur during formation of adiabatic shear band. The diffusion mechanism may be short-range diffusion driven by high-speed deformation and high temperature rise.

Abstract: A deep understanding of adiabatic shear fracture (ASF) during serrated chip formation is essential to explore the material removal mechanism of high speed cutting (HSC). This paper aims to reveal the microscopic details of ASF in serrated chips. The material to investigate was AISI 1045 steel of different hardness grades, and the micro-structural analysis was conducted using optical and scanning electronic microscopes. The investigation showed that at the hardness of HRC50, most fractured surfaces were covered by a large number of dimples elongated along the shear direction, indicating that the fundamental cause of the serrated chip generation is the deformation localization of the adiabatic shear followed by ductile damage fracture in primary shear zones. The higher the material hardness is, the easier the adiabatic shear and ductile fracture take place. A new model was then proposed to interpret the ductile fracture due to adiabatic shear governed by the nucleation, growth and coalescence of micro-voids during serrated chip formation.

Abstract: Adiabatic shear banding during high speed machining is important to understand material removal mechanisms. This paper investigates the microstructure of adiabatic shear bands (ASBs) in the serrated chips produced during the high speed machining of AISI 1045 hardened steel. Optical microscope, scanning electronic microscope(SEM) and transmission electronic microscope(TEM) were used to explore the microstructural characteristics. It was found that there are two types of adiabatic shear bands. One is the deformed adiabatic shear band composed of a significantly deformed structure generated in a range of low cutting speeds, and the other is the transformed adiabatic shear band composed of very small equiaxed grains generated under high cutting speeds. The results indicated that the deformed band has a tempered martensite structure that formed through large plastic deformation and the transformed band has experienced a dynamic recrystallization process.