Papers by Keyword: Serrated Chip

Abstract: Serrated chips were a universal phenomenon and it had a significant effect on cutting process. In this paper, single tooth dry cutting of TC11 titanium alloy were conducted on a five-axis CNC machine using Stellram milling cutter with a diameter of 32 mm. Both chip macroscopic morphology and microcosmic morphology of TC11 titanium alloy were studied in-depth examining the impact of cutting speed and feed rate to the serrated chips. The results showed that: with the increase of cutting speed, the chip morphology of titanium alloy TC4 experienced a change process from the hair bar to a “C” shape and then become a long strip. The critical cutting speed of TC11 for serrated chips was found at 80 m/min and the critical feed rate to form serrated chip was defined as 0.05mm/z. With the increasing of cutting speed, the extent of chip serration was significantly enhanced. Increasing cutting speed can decrease the feed rate to form serrated chips.

Abstract: The research of the simulation for high speed cutting is usually based on 2D modeling by now, and the 3D simulation is few. Because the cutting process is a 3D deformation of workpiece, it's badly in need of the research on 3D finite element simulation of cutting process for further reveal the mechanism of high speed cutting. The 3D simulation of inclined cutting of hardened 45 steel (45HRC) is carried out base on ABAQUS. The forming process of serrated chip is simulated by adopting the Johnson-cook material modeling and separation criterion of shear failure. The change of chip morphology, chip flow angle and deformation coefficient of width under different rake angle and cutting depth are analyzed. The results show that the segment degree of chip becomes larger with the decrease of rake angle and increase of cutting depth. The chip flow angle is not effected by rake angle and its value is approximately equal to tool cutting edge inclination angle, an it increases with the increase of cutting depth. The deformation coefficient of width increase with the decrease of rake angle and increase of cutting depth.

Abstract: This paper analyzed the serrated chip formation process and mechanism in high-speed milling of nickel-based superalloy GH706. Firstly, analyzed two theories of serrated chip formation: cyclical fracture theory and adiabatic shear theory. Secondly, used the simulation of chip formation in high-speed milling of GH706 process, and concluded that the two major theories have achieved dialectical unity when machining for such difficult machining materials. Finally experiments for serrated chip, when cutting speed exceeded 200/min, serrated chips became more obvious. Research has shown that for nickel-based superalloy, adiabatic shear instability of the unstable thermoplastic in the first deformation zoon become the leader of formation of serrated chip, followed as the speed increases, fracture aggravate the degree of serrated chip.

Abstract: High-temperature alloy can easily produce jagged chips in high-speed cutting conditions. The serrated chips will lead to the volatility of cutting force and impact the processing efficiency and quality. The formation mechanism of serrated chip has important significance to improve processing quality and efficiency. As the serrated chips have very short generation time, it is very hard to measure the changes of the stress, strain and temperature during the formation of serrated chips in experimental method. And it is more difficult to carry out quantitative and qualitative analysis. So it has been the research priorities and difficulties in the field of metal cutting. In this paper, both the finite element method simulation and experimental method are used to study the formation mechanism of serrated chip, deformation of material and the degree of variation of jagged. It has an important reference value to select cutting parameters for high-temperature alloy cutting.

Abstract: Under the condition of cutting speed 10-300m/min, rake angle -10°、0°、10°and cutting depths 0.05mm、0.1mm and 0.2mm, the experiment study of adiabatic shear serrated chip and surface roughness are carried out. The influence of cutting condition on serrated chip is analyzed through the metallographic observation of obtained chip. By the measurement of finished surface, the influenc of cutting condition and adiabatic shear on surface roughness is also investigated. The rusults show that the reason lead to serrated chip in high speed cutting of Ti6Al4V is adiabatic shear, not the periodic fracture.The adiabatic shear serrated chip is easier appear and the degree of segment is more large under the condition of higher cutting speed, larger cutting depth and smaller rake angle. The surface roughness is smaller when the cutting speed is higher, cutting depth is larger, and rake angle is smaller.

Abstract: Hard cutting process is easy to produce serrated chip. Hardened steel GCr15 as the object for the study, chip morphology was studied on hard cutting test and chip cross-sectional microscopic analysis methods. The boundaries of ribbon cuttings to serrated chips cutting was determined, under certain conditions of PCBN cutting tool cutting precision hardened steel GCr15, and form a quantitative description of the chip. With the increase in the amount of cutting, serrated chips have the degree of improved trend, in which the most significant impact of cutting speed, while the hardness increases, the degree of sawtooth also increases. Hard cutting research will enrich the theory provides a theoretical basis for the choice of cutting parameters.

Abstract: For most of materials, a chip transformation from continuous to serrated takes place at a relative high cutting speed which is called the critical cutting speed (CCS). Serrated chips at CCS have different characteristics from those at higher cutting speeds. In this paper, the chip transformation is analytically investigated. The deformation in the primary shear zone (PSZ) during the transformation is analyzed. The critical shear strain at CCS for chip transformation is proposed. Cutting Experiments are carried out with four metals, and metallographical and morphological investigations on the chip transformation are conducted. The results show that serrated chips can be produced if the shear localization along a shear plane occurs before the shear plane reaches to the middle of PSZ. At CCS, the flow stress of the shear plane passing through the PSZ reaches maximum at the middle of PSZ and then decreases with further straining. The high thickness of localized shear bands makes the serrated chip at CCS look as a wave. At CCS, the shear strain of chip segments is approximately equal to the critical shear strain for chip transformation. Influences of material hardess (brittleness) on chip transformation are also discussed.

Abstract: In this paper, a novel model combining the microstructure prediction model and a modified constitutive model of the Johnson-Cook (JC) model was developed and embedded into FEM software via the user subroutine. The chip formation and microstructure evolution in high speed cutting of Ti-6Al-4V alloy were simulated. The results indicated that dynamic recrystallization mainly happened in adiabatic shear bands (ASBs), where the grain size had a big decline. Then FEM simulations were carried out to investigate the effect of cutting velocity, uncut chip thickness, and the rake angle on the ASBs width of the serrated chips. It can be concluded that the width of ASB increases with the increasing of cutting depth and cutting velocity, and decreases with the increasing of rake angle of the tool.

Abstract: In this paper, a novel model combining the microstructure prediction model and a modified constitutive model of the Johnson-Cook (JC) model was developed and embedded into FEM software via the user subroutine. The chip formation and microstructure evolution in high speed cutting of Ti-6Al-4V alloy were simulated based on the presented model. The results indicated that dynamic recrystallization mainly happened in ASBs, where the grain size had a big decline. According to the variation of cutting temperature and grain size of microstructure, the mechanism of the adiabatic shear bands (ASBs) formation was investigated deeply and concluded that dynamic recrystallization was the root cause of the serrated chip formation.

Abstract: For the high speed cutting process of hardened 45 steel (45HRC), a finite element simulation of cutting deformation, cutting force and cutting temperature is finished with the large general finite element software ABAQUS. Through the building of geometry model, material model and heat conduction model, also the determination of boundary conditions, separation rule and friction condition, a thermal mechanical coupling finite element model of high speed cutting for hardened 45 steel is built. The serrated chip, cutting force and cutting temperature can be predicted. The comparison of experiment and simulation shows the validity of the model. The influence of cutting parameters on cutting process is investigated by the simulation under different cutting depthes and rake angles. The results show that as the increase of rake angle, the segment degree, cutting force and cutting temperature decrease. But the segment degree, also the cutting force and cutting temperature increase with the increase of cutting depth. This study is useful for the selection of cutting parameters of hardened steel.