As the cutting speed goes higher, the mechanism of chip deformation will be changed significantly, i.e., continuous chip in low cutting speed will shift to serrated chip with shear localization. For the shear localize...As the cutting speed goes higher, the mechanism of chip deformation will be changed significantly, i.e., continuous chip in low cutting speed will shift to serrated chip with shear localization. For the shear localized chip, the parameters used to assess the chip deformation for continuous chip, such as shorten coefficient ξ, shear angle φ and shear strain ε, can not describe the chip deformation correctly or comprehensively. This paper deals with the assessment of chip deformation of shear localization. There are two deformation regions in shear localized chip, one is the chip segment body with relative smaller plastic deformation, another one is the boundary between segments with shear localization, so called shear band. Considering the two distinct deformation regions, two parameters are used to define their deformation respectively. According to the analysis of chip formation process, the equations have been deduced to calculate the shear strains of shear band ε, shear strain of chip segment ε 1 and shear rate so that the shear localized chip deformation can be assessed correctly and comprehensively. By use of this assessment, the chip deformation in machining selenium treated stainless steel (STSS) and common stainless steel at various cutting conditions is investigated. The experiment results obtained by the machining of stainless steel prove that: (1) the shear strain and strain rate increase with the increasing of cutting speed; (2) the shear strain in shear band can be over 10 when cutting speed exceeding 200 m/min for both types of stainless steel, and it is much higher than the strain of chip segment. The difference will be enlarged as the cutting speed increasing; (3) As the comparison, the shear strain for the STSS is a little lower than that for JIS304; (4) The stain rate is extremely high (= 2.5×10 5 1/s ). In range of cutting speed less than 180 m/min, the strain rate for STSS is lower than that for JIS304. However, when the cutting speed is higher than 180 m/min, the strain rate for STSS is higher than that for JIS304.展开更多
In high speed milling of titanium alloys the high rate of tool failure is the main reason for its high manufacturing cost. In this study,fractured tools which were used in a titanium alloys 5-axis milling process have...In high speed milling of titanium alloys the high rate of tool failure is the main reason for its high manufacturing cost. In this study,fractured tools which were used in a titanium alloys 5-axis milling process have been observed both in the macro scale using a PG-1000 light microscope and in the micro scale using a Scanning Electron Microscope (SEM) respectively. These observations indicate that most of these tool fractures are the result of tool chipping. Further analysis of each chipping event has shown that beachmarks emanate from points on the cutting edge. This visual evidence indicates that the cutting edge is failing in fatigue due to cyclical mechanical and/or thermal stresses. Initial analyses explaining some of the outlying conditions for this phenomenon are discussed. Future analysis regarding determining the underlying causes of the fatigue phenomenon is then outlined.展开更多
文摘As the cutting speed goes higher, the mechanism of chip deformation will be changed significantly, i.e., continuous chip in low cutting speed will shift to serrated chip with shear localization. For the shear localized chip, the parameters used to assess the chip deformation for continuous chip, such as shorten coefficient ξ, shear angle φ and shear strain ε, can not describe the chip deformation correctly or comprehensively. This paper deals with the assessment of chip deformation of shear localization. There are two deformation regions in shear localized chip, one is the chip segment body with relative smaller plastic deformation, another one is the boundary between segments with shear localization, so called shear band. Considering the two distinct deformation regions, two parameters are used to define their deformation respectively. According to the analysis of chip formation process, the equations have been deduced to calculate the shear strains of shear band ε, shear strain of chip segment ε 1 and shear rate so that the shear localized chip deformation can be assessed correctly and comprehensively. By use of this assessment, the chip deformation in machining selenium treated stainless steel (STSS) and common stainless steel at various cutting conditions is investigated. The experiment results obtained by the machining of stainless steel prove that: (1) the shear strain and strain rate increase with the increasing of cutting speed; (2) the shear strain in shear band can be over 10 when cutting speed exceeding 200 m/min for both types of stainless steel, and it is much higher than the strain of chip segment. The difference will be enlarged as the cutting speed increasing; (3) As the comparison, the shear strain for the STSS is a little lower than that for JIS304; (4) The stain rate is extremely high (= 2.5×10 5 1/s ). In range of cutting speed less than 180 m/min, the strain rate for STSS is lower than that for JIS304. However, when the cutting speed is higher than 180 m/min, the strain rate for STSS is higher than that for JIS304.
文摘In high speed milling of titanium alloys the high rate of tool failure is the main reason for its high manufacturing cost. In this study,fractured tools which were used in a titanium alloys 5-axis milling process have been observed both in the macro scale using a PG-1000 light microscope and in the micro scale using a Scanning Electron Microscope (SEM) respectively. These observations indicate that most of these tool fractures are the result of tool chipping. Further analysis of each chipping event has shown that beachmarks emanate from points on the cutting edge. This visual evidence indicates that the cutting edge is failing in fatigue due to cyclical mechanical and/or thermal stresses. Initial analyses explaining some of the outlying conditions for this phenomenon are discussed. Future analysis regarding determining the underlying causes of the fatigue phenomenon is then outlined.
