Skip to main content
SpringerLink
Log in

A reliable method for predicting serrated chip formation in high-speed cutting: analysis and experimental verification

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Serrated chip formation influences almost every aspect of a high-speed cutting (HSC) process. This paper aims to develop a reliable method to accurately predict such chip formation processes. To this end, a systematic finite element analysis was carried out and a series of HSC experiments were conducted on a heat treated AISI 1045 steel. It was found that the integrative use of the Johnson–Cook thermal-viscoplastic constitutive equation, Johnson–Cook damage criterion for chip separation, and the modified Zorev’s friction model can precisely predict the serrated chip formation in HSC without artificial assumptions. This advancement has removed the major barrier in the current machining investigations by numerical simulation. The present study also found that the tool rake angle has a significant effect on serrated chip formation. As the rake angle increases, the chip sawtooth degree and cutting forces decrease, but the chip segmentation frequency increases.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Klocke F, Raedt HW, Hoppe S (2001) 2D-FEM simulation of the orthogonal high speed cutting process. Mach Sci Technol 5(3):323–340

    Article  Google Scholar 

  2. Baker M, Rosier J, Siemers C (2002) A finite element model of high speed metal cutting with adiabatic shearing. Comput Struct 80:495–513

    Article  Google Scholar 

  3. Baker M (2006) Finite element simulation of high-speed cutting forces. J Mater Process Technol 176:117–126

    Article  Google Scholar 

  4. Hortig C, Svendsen B (2007) Simulation of chip formation during high-speed cutting. J Mater Process Technol 186:66–76

    Article  Google Scholar 

  5. Rhim S, Oh S (2006) Prediction of serrated chip formation in metal cutting process with new flow stress model for AISI 1045 steel. J Mater Process Technol 171:417–422

    Article  Google Scholar 

  6. Ng EG, EI-Wardany TI, Dumitrescu M, Elbestawi MA (2002) Physics-based simulation of high speed machining. Mach Sci Technol 6:301–329

    Article  Google Scholar 

  7. Umbrello D (2008) Finite element simulation of conventional and high speed machining of Ti6Al4V alloy. J Mater Process Technol 196:79–87

    Article  Google Scholar 

  8. Johnson GR, Cook WHA (1983) Constitutive model and data for metals subjected to large strain, high strain rates, and high temperature. In: Proceedings of the 7th International Symposium on Ballistics, Hague, the Netherlands, pp 541–547

  9. Zerilli FJ, Armstrong RW (1987) Dislocation-mechanics-based constitutive relations for material dynamics calculation. J Appl Phys 5:1816–1825

    Article  Google Scholar 

  10. Gao CY, Zhang LC (2010) A constitutive model for dynamic plasticity of FCC metals. Mater Sci Eng A 527:3138–3143

    Article  Google Scholar 

  11. Davies MA, Cao Q, Cooks AL (2003) On the measurement and prediction of temperature fields in machining AISI 1045 Steel. CIRP Ann Manuf Technol 52(1):77–80

    Article  Google Scholar 

  12. Li GH (2009) Prediction of adiabatic shear in high speed machining based on linear pertubation analysis. Ph.D thesis, Dalian University of Technology, China

  13. Komvopoulos K, Erpenbeck AS (1991) Finite element modeling of orthogonal metal cutting. ASME J Eng Ind 113:253–267

    Article  Google Scholar 

  14. Lin ZC, Lo SP (1997) Ultra-precision orthogonal cutting simulation for oxygen-free high-conductivity copper. J Mater Process Technol 55:281–291

    Article  Google Scholar 

  15. Mamalis AG, Horvath M, Branis AS, Manolakos DE (2001) Finite element simulation of chip formation in orthogonal metal cutting. J Mater Process Technol 110:19–27

    Article  Google Scholar 

  16. Huang JM, Black JT (1996) An evaluation of chip separation criteria for the FEM simulation of machining. J Manuf Sci Eng 118:545–554

    Article  Google Scholar 

  17. Shet C, Deng X (2003) Residual stresses and strains in orthogonal metal cutting. Int J Mach Tools Manuf 43:573–587

    Article  Google Scholar 

  18. Li K, Gao XL, Sutherland JW (2002) Finite element simulation of the orthogonal metal cutting process for qualitative understanding of the effects of crater wear on the chip formation process. J Mater Process Technol 127:309–324

    Article  Google Scholar 

  19. Strenkowski JS, Carroll JT (1985) A finite element model of orthogonal metal cutting. ASME J Eng Ind 107:349–354

    Article  Google Scholar 

  20. Xie JQ, Bayoumi AE, Zbib HM (1998) FEA modeling and simulation of shear localized chip formation in metal cutting. Int J Mach Tools Manuf 38:1067–1087

    Article  Google Scholar 

  21. Lin ZC, Pan WC (1993) Thermoelastic plastic large deformation model for orthogonal cutting with tool flank wear, part I: computational procedures. Int J Mech Sci 35:829–840

    Article  MATH  Google Scholar 

  22. Lin ZC, Lin YY (2001) A study of oblique cutting for different low cutting speeds. J Mater Process Technol 115:313–325

    Article  Google Scholar 

  23. Zhang LC (1999) On the separation criteria in the simulation of orthogonal metal cutting using the finite element method. J Mater Process Technol 89–90:273–278

    Article  Google Scholar 

  24. Pantale O, Bacaria JL, Dalverny O, Rakotomalala R, Caperaa S (2004) 2D and 3D numerical models of metal cutting with damage effects. Comput Methods Appl Mech Eng 193:4383–4399

    Article  MATH  Google Scholar 

  25. Mabrouki T, Rigal JF (2006) A contribution to a qualitative understanding of thermo-mechanical effects during chip formation in hard turning. J Mater Process Technol 176:214–221

    Article  Google Scholar 

  26. Vaziri MR, Salimi M, Mashayekhi M (2010) A new calibration method for ductile fracture models as chip separation criteria in machining. Simul Mod Pract Theory 18:1286–1296

    Article  Google Scholar 

  27. Cockroft MG, Latham DJ (1968) Ductility and workability of metals. J Inst Met 96:33–39

    Google Scholar 

  28. McClintock FA (1968) A criterion for ductile fracture by the growth of holes. J Appl Mech 35:363–371

    Article  Google Scholar 

  29. Johnson GR, Cook WH (1985) Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21(1):31–48

    Article  Google Scholar 

  30. Zorev NN (1963) Inter-relationship between shear processes occurring along tool face and shear plane in metal cutting. International Research in Production Engineering ASME: International Production Engineering Research Conference, Pittsburgh, pp 42–49

    Google Scholar 

  31. Ozel T, Altan T (2000) Determination of workpiece flow stress and friction at the chip–tool contact for high-speed cutting. Int J Mach Tools Manuf 40:133–152

    Article  Google Scholar 

  32. Schulz H, Abele E, Sahm A (2001) Material aspects of chip formation in HSC machining. CIPP Ann-Manuf Technol 50(1):45–48

    Article  Google Scholar 

  33. Zhao QT, Wu GQ, Sha W (2010) Deformation of titanium alloy Ti–6Al–4V under dynamic compression. Comput Mater Sci 50(2):516–526

    Article  Google Scholar 

  34. Sun J, Guo YB (2009) Material flow stress and failure in multiscale machining titanium alloy Ti–6Al–4V. Int J Adv Manuf Technol 41(7–8):651–659

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Mechanical and Manufacturing Engineering, University of New South Wales, NSW,, 2052, Sydney, Australia

    Chunzheng Duan & Liangchi Zhang

  2. School of Mechanical Engineering, Dalian University of Technology, 116024, Dalian, People’s Republic of China

    Chunzheng Duan

Authors
  1. Chunzheng Duan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Liangchi Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Liangchi Zhang.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Duan, C., Zhang, L. A reliable method for predicting serrated chip formation in high-speed cutting: analysis and experimental verification. Int J Adv Manuf Technol 64, 1587–1597 (2013). https://doi.org/10.1007/s00170-012-4125-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-012-4125-0

Keywords

Search

Navigation