Adiabatic Shear Bands in 30CrNi_3MoV Structural Steel Induced during High Speed Cutting

The width and spacing of adiabatic shear bands (ASBs) in the serrated chips generated during high speed orthogonal cutting of 30CrNi3MoV structurai steel were measured by opticai microscopy (OM), the temperature rise in the shear band was estimated. The microstructures of the ASBs were also characterized by SEM and TEM. The results show that the width and spacing of ASBs decrease with the increase of the cutting speed. The further observations show that the microstructure between the matrix and the center of the ASB gradually changes, and that the martensitic phase transformation, carbide precipitation and recrystallization may occur in the ASB.

A Review of Microstructural Evolution in the Adiabatic Shear Bands Induced by High Speed Machining

Investigations made by the authors and collaborators into the microstructural and fracture aspects of adiabatic shear bands （ASBs） of the hardened steels and Ti alloys induced by high speed machining （HSM） are briefly reviewed. The principal findings are the following： （a） the microstructure inside the ASBs varies from the band center to the normal chip material, the gradient microstructures are found; （b） the HSM can produce two types of ASBs with increasing in cutting speed, the deformed shear bands formed at lower cutting speed and the transformed shear bands formed at higher cutting speed; （c） the very small equiaxed recrystallized grains are observed in the center of the ASBs, the dynamic recrystallization and phase transformation may occur simultaneously during the formation of the transformed ASBs; （d） The dynamic rotational recrystallization is the origin of the equiaxed grains in the center of the ASBs. A microstructural evolution model in ASBs produced during HSM for the harden steel is proposed; （e） the microstructural pattern of fracture surface is characterised by the elongated dimples. A microcosmic adiabatic shear fracture model during HSM of the hardened steel is built up.

Multi-scale crystal plasticity finite element simulations of the microstructural evolution and formation mechanism of adiabatic shear bands in dual-phase Ti20C alloy under complex dynamic loading

A dynamic compression test was performed on α+β dual-phase titanium alloy Ti20C using a split Hopkinson pressure bar.The formation of adiabatic shear bands generated during the compression process was studied by combining the proposed multi-scale crystal plasticity finite element method with experimental measurements.The complex local micro region load was progressively extracted from the simulation results of a macro model and applied to an established three-dimensional multi-grain microstructure model.Subsequently,the evolution histories of the grain shape,size,and orientation inside the adiabatic shear band were quantitatively simulated.The results corresponded closely to the experimental results obtained via transmission electron microscopy and precession electron diffraction.Furthermore,by calculating the grain rotation and temperature rise inside the adiabatic shear band,the microstructural softening and thermal softening effects of typical heavily-deformed α grains were successfully decoupled.The results revealed that the microstructural softening stress was triggered and then stabilized(in general)at a relatively high value.This indicated that the mechanical strength was lowered mainly by the grain orientation evolution or dynamic recrystallization occurring during early plastic deformation.Subsequently,thermal softening increased linearly and became the main softening mechanism.Noticeably,in the final stage,the thermal softening stress accounted for 78.4% of the total softening stress due to the sharp temperature increase,which inevitably leads to the stress collapse and potential failure of the alloy.

Adiabatic shear localization evolution for steel based on the Johnson-Cook model and gradient-dependent plasticity

Gradient-dependent plasticity is introduced into the phenomenological Johnson-Cook model to study the effects of strainhardening, strain rate sensitivity, thermal-softening, and microstructure. The microstructural effect （interactions and interplay among microstructures） due to heterogeneity of texture plays an important role in the process of development or evolution of an adiabatic shear band with a certain thickness depending on the grain diameter. The distributed plastic shear strain and deformation in the shear band are derived and depend on the critical plastic shear strain corresponding to the peak flow shear stress, the coordinate or position, the internal length parameter, and the average plastic shear strain or the flow shear stress. The critical plastic shear strain, the distributed plastic shear strain, and deformation in the shear band are numerically predicted for a kind of steel deformed at a constant shear strain rate. Beyond the peak shear stress, the local plastic shear strain in the shear band is highly nonuniform and the local plastic shear deformation in the band is highly nonlinear. Shear localization is more apparent with the increase of the average plastic shear strain. The calculated distributions of the local plastic shear strain and deformation agree with the previous numerical and experimental results.

Adiabatic Shear Localization for Steels Based on Johnson-Cook Model and Second-and Fourth-Order Gradient Plasticity Models

To consider the effects of the interactions and interplay among microstructures, gradient-dependent models of second- and fourth-order are included in the widely used phenomenological Johnson-Cook model where the effects of strain-hardening, strain rate sensitivity, and thermal-softening are successfully described. The various parameters for 1006 steel, 4340 steel and S-7 tool steel are assigned. The distributions and evolutions of the local plastic shear strain and deformation in adiabatic shear band （ASB） are predicted. The calculated results of the second- and fourth- order gradient plasticity models are compared. S-7 tool steel possesses the steepest profile of local plastic shear strain in ASB, whereas 1006 steel has the least profile. The peak local plastic shear strain in ASB for S-7 tool steel is slightly higher than that for 4340 steel and is higher than that for 1006 steel. The extent of the nonlinear distribution of the local plastic shear deformation in ASB is more apparent for the S-7 tool steel, whereas it is the least apparent for 1006 steel. In fourth-order gradient plasticity model, the profile of the local plastic shear strain in the middle of ASB has a pronounced plateau whose width decreases with increasing average plastic shear strain, leading to a shrink of the portion of linear distribution of the profile of the local plastic shear deformation. When compared with the sec- ond-order gradient plasticity model, the fourth-order gradient plasticity model shows a lower peak local plastic shear strain in ASB and a higher magnitude of plastic shear deformation at the top or base of ASB, which is due to wider ASB. The present numerical results of the second- and fourth-order gradient plasticity models are consistent with the previous numerical and experimental results at least qualitatively.

Formation of adiabatic shearing band for high-strength Ti-5553 alloy:A dramatic thermoplastic microstructural evolution

By using split Hopkinson pressure bar, optical microscopy and electronic microscopy, we investigate the influence of initial microstructures on the adiabatic shear behavior of high-strength Ti-5Al-5V-5Mo-3Cr(Ti-5553) alloy with lamellar microstructure and bimodal microstructure. Lamellar alloy tends to form adiabatic shearing band(ASB) at low compression strain, while bimodal alloy is considerably ASBresistant. Comparing with the initial microstructure of Ti-5553 alloy, we find that the microstructure of the ASB changes dramatically. Adiabatic shear of lamellar Ti-5553 alloy not only results in the formation of recrystallized β nano-grains within the ASB, but also leads to the chemical redistribution of the alloying elements such as Al, V, Cr and Mo. As a result, the alloying elements distribute evenly in the ASB.In contrast, the dramatic adiabatic shear of bimodal alloy might give rise to the complete lamination of the globular primary a grain and the equiaxial prior β grain, which is accompanied by the dynamic recrystallization of a lamellae and β lamellae. As a result, ASB of bimodal alloy is composed of a/β nanomultilayers. Chemical redistribution does not occur in ASB of bimodal alloy. Bimodal Ti-5553 alloy should be a promising candidate for high performance armors with high mass efficiency due to the processes high dynamic flow stress and excellent ASB-resistance.

Analysis of Adiabatic Shearing Failure Mechanism for Aluminum Matrix Composites Based on Experimental and Numerical Simulation

Adiabatic shear behavior and the corresponding mechanism of TiB2/Al composites were researched by split Hopkinson pressure bar （SHPB）.Results show that the flow stresses of the TiB2/Al composites exhibit softening tendency with the increasing of strain rates. All the composites fail in splitting and cutting with a 45 degree, and the phase transformed bands of molten aluminum are found on the adiabatic shear layers. The deformation behavior and shear localization of the TiB2/Al composites specimens were simulated by finite element code MSC.Marc. The Johnson-Cook model was used to describe the thermo-viscoplastic response of the specimen material. There was unanimous between the numerical result and the experimental result on the location of the adiabatic shear band. From the numerical simulation and experiment, it was concluded that the instantaneous failure of the composite was ascribed due to the local low strength area where the formation of adiabatic shear band was, and the stress condition had significant effect on the initiation and propagation of adiabatic shear band （ASB）.

Microstructural Characterization of the Shear Bands in Fe-Cr-Ni Single Crystal by EBSD

An investigation has been made into the microstructural characterization of the shear bands generated under high-strain rate （≈10^4 s^-1） deformation in Fe-15%Cr-15%Ni single crystal by EBSD-SEM （electron backscatter diffraction-scanning electron microscopy）, TEM （transmission electron in microscopy） and HREM （high- resolution electron microscopy）. The results reveal that the propagation of the shear band exhibits an asymmetrical behavior arising from inhomogenous distribution in plasticity in the bands because of different resistance to the collapse in different crystallographic directions; The γ-ε-α′phase transformations may take place inside and outside the bands, and these martensitic phases currently nucleate at intersections either between the twins and deformation bands or between the twins and ε-sheet. Investigation by EBSD shows that recrystallization can occur in the bands with a grain size of an average of 0.2μm in diameter. These nano-grains are proposed to attribute to the results of either dynamic or static recrystallization, which can be described by the rotational recrystallization mechanism. Calculation and analysis indicate that the strain rate inside the shear band can reach 2.50×10^6 s^-1, which is higher, by two or three orders of magnitude, than that exerted dynamically on the specimen tested.

Ballistic tests on hot-rolled Ti-6Al-4V plates:Experiments and numerical approaches

Superior ballistic performance and the lightweight character of Ti alloys are considered as main reasons for their use in armour applications against a broad spectrum of ballistic threats,e.g.bullet,fragment or blast impact.Because dynamic loading caused by typical penetrators is characterized by high strain rates,only specific test methods allow a closer investigation of the respective material behaviour.In the present study,quasi-static and dynamic compression tests as well as ballistic tests were conducted on a twophase a+βalloy Ti-6Al-4V(in m%)manufactured by hot-rolling.Post-deformation heat treatments,influencing microstructure and mechanical properties were applied in order to compare three different microstructural configurations:as-rolled,mill-annealed and bimodal.While,on the one hand,ballistic tests were employed for the determination of the ballistic limit velocity v_(50),compression tests,on the other hand,delivered essential input parameters for the application of the Johnson-Cook constitutive model in a finite element simulation of the impact event.The comparison of experimental results to simulation results was supplemented by means of microstructural characterization of tested samples with the focus set on the prevalently observed deformation and damage mechanisms,as for example adiabatic shearing.

Effect of deep cryogenic treatment on the microstructural,mechanical and ballistic properties of AA7075-T6 aluminum alloy

The study focused on investigating the effect of Deep Cryogenic Treatment(DCT)on the mechanical and ballistic properties of AA7075-T6 aluminum alloy.The microstructure,microhardness,tensile strength,and impact strength of the Base Material(BM)and DCT-treated 7075 samples were analyzed through metallographic analysis and mechanical tests.The microstructure of the DCT-treated 7075 samples revealed fine grains and a distribution of secondary phase particles.The tensile strength,impact strength,and microhardness of DCT-treated samples increased by 7.41%,4%,and 9.68%,respectively,compared to the BM samples.The fractography analysis of the tensile samples showed cleavage facets,microvoids,and dimples in both the samples.The ballistic behavior of the BM and DCT target plates were studied by impacting hard steel core projectiles at a velocity of 750±10 m/s.The target plates failed due to petaling and ductile hole enlargement,and the depth of penetration(DOP)of the DCT target was less than that of the BM target,indicating a higher ballistic resistance.The post-ballistic microstructure examination of the target plates showed the formation of an Adiabatic Shear Band(ASB)without any cracks.It was concluded that the DCT treatment improved the mechanical and ballistic properties of the aluminum alloy due to grain refinement and high dislocation density.

Failure mode change and material damage with varied machining speeds:a review

High-speed machining(HSM) has been studied for several decades and has potential application in various industries, including the automobile and aerospace industries. However,the underlying mechanisms of HSM have not been formally reviewed thus far. This article focuses on the solid mechanics framework of adiabatic shear band(ASB) onset and material metallurgical microstructural evolutions in HSM. The ASB onset is described using partial differential systems. Several factors in HSM were considered in the systems, and the ASB onset conditions were obtained by solving these systems or applying the perturbation method to the systems. With increasing machining speed, an ASB can be depressed and further eliminated by shock pressure. The damage observed in HSM exhibits common features. Equiaxed fine grains produced by dynamic recrystallization widely cause damage to ductile materials, and amorphization is the common microstructural evolution in brittle materials. Based on previous studies, potential mechanisms for the phenomena in HSM are proposed. These include the thickness variation of the white layer of ductile materials. These proposed mechanisms would be beneficial to deeply understanding the various phenomena in HSM.

The modified temperature term on Johnson-Cook constitutive model of AZ31 magnesium alloy with {0002} texture

The dynamic compression experiments with Split-Hopkinson Pressure Bar(SHPB)were performed on AZ31 magnesium alloy rolled sheet specimens in the normal direction(AZ31-ND)with{0002}texture at the temperature of 293-523 K and the strain rate of 0.001-2200 s^−1.The temperature term in Johnson-Cook(JC)constitutive model had been reasonably modified.This advantage made constitutive model promising for decribing the dynamic deformation behavior of AZ31-ND with{0002}texture more accurately.The obtained true stress-true plastic strain curves agreed well with the measured results in a wide range of strain rates and temperatures.The thermal softeninging,strain and strain rate hardening effect on the AZ31-ND with{0002}texture were discussed.The adiabatic shear band(ASB)of AZ31-ND with{0002}texture hat shaped specimen was successfully predicted by combining modified JC constitutive model and numerical simulation,which was also validated by Electron Back-Scattered Diffraction(EBSD)map under the same boundary condition.

Formation of adiabatic shear band and deformation mechanisms during warm compression of Ti–6Al–4V alloy

Adiabatic shear band （ASB） was narrow region where softening occurred and concentrated plastic defor- mation took place. In present study, the effects of height reduction and deformation temperature on ASB were investigated by means of optical microscopy （OM） and scanning electron microscopy （SEM）. And the deformation mechanisms within the shear band were discussed thor- oughly with the help of transmission electron microscopy （TEM）. There is a critical strain for the formation of ASB during warm compression of Ti-6AI-4V alloy. The width of ASB increases with height reduction increasing. Elon- gated alpha grains within shear band grow up with defor- mation temperature increasing. Some ultrafine grains that confirm the occurrence of dynamic recrystallization are observed within shear band during warm compression of Ti-6AI-4V alloy.

Microstructural softening induced adiabatic shear banding in Ti-23Nb-0.7Ta-2Zr-O gum metal

Ti-23Nb-0.7Ta-2Zr-O gum metal(GM)is an attractive candidate material for applications that require superior mechanical properties.In our earlier investigation of the GM[1],geometrical softening and the generation of adiabatic shear bands(ASBs)were proposed as primary reasons for the documented anisotropic impact response.In the present study,electron backscattered diffraction(EBSD)analysis reveals two different deformed microstructures,i.e.,deformed ultrafine grains(UFGs)and dynamically recrystallized UFGs,formed in the ASBs of GM samples processed by extrusion equal channel angular pressing(ECAP),respectively.Additional calculation of temperature rise during dynamic compression suggests that the above microstructure differences in the ASBs was originated from their different maximum ASB temperatures(608 K for extruded GM and 1159 K for ECAP-processed GM).Moreover,our calculation on the temperature at the onset of ASBs indicates that microstructural softening is the primary cause for the development of ASBs in both extruded GM(321 K)and ECAP-processed GM(331 K).

Adiabatic shear banding of hot-rolling Ti–6Al–4V alloy subjected to dynamic shearing and uniaxial dynamic compression

Effect of stress state including dynamic shearing and uniaxial dynamic compression on adiabatic shear banding(ASBing) of hot-rolling Ti–6Al–4V(TC4) alloy was investigated. The absorbed energy of specimen before failure was calculated to evaluate the susceptibility to adiabatic shear band(ASB) of TC4 alloy quantitatively.Results show that the susceptibility to ASB of hot-rolling TC4 alloy exhibits obvious anisotropy under both dynamic shearing and uniaxial dynamic compression conditions, but the anisotropy of susceptibility to ASB under dynamic shearing condition exhibits an opposite tendency with that under uniaxial dynamic compression condition. Under the condition of uniaxial dynamic compression, material shows the highest susceptibility to ASB when loaded along transverse direction(TD) of the hot-rolling TC4, while the lowest susceptibility when loaded along rolling direction(RD). However, under the condition of dynamic shearing,the material behaves in the opposite way, demonstrating the lowest susceptibility when loaded along TD of the hotrolling TC4, while the highest susceptibility when loaded along RD.

Superior dynamic shear properties by structures with dual gradients in medium entropy alloys

Structures with single gradient and dual gradients have been designed and fabricated in an Al_(0.5)Cr_(0.9)FeNi_(2.5)V_(0.2) medium entropy alloy.Structures with dual gradients(with increasing grain size and a decreasing volume fraction of nanoprecipitates from the surface to the center)were observed to show much better dynamic shear properties compared to both structures with single grainsize gradient and coarse-grained structures with homogeneously distributed nanoprecipitates.Thus,the dual gradients have a synergetic strengthening/toughening effect as compared to the sole effect of a single gradient and the sole precipitation effect.Initiation of the adiabatic shear band(ASB)is delayed and propagation of ASB is slowed down in structures with dual gradients compared to structures with single gradients,resulting in better dynamic shear properties.A higher magnitude of strain gradient and higher density of geometrically necessary dislocations are induced in the structures with dual gradients,resulting in extra strain hardening.Higher density dislocations,stacking faults,and Lomer-Cottrell locks can be accumulated by the interactions between these defects and B2/L1_(2) precipitates,due to the higher volume fraction of nanoprecipitates in the surface layer of the structures with dual gradients,which could retard the early strain localization in the surface layer for better dynamic shear properties.

LOCALIZED SUPERPLASTIC BEHAVIOUR INα-TITANIUM AT HIGH STRAIN RATE

The microstructure of x-Ti/ mild steel composite fabricated by using constant stand-off cladding technique was observed with optical microscopy, SEM and TEM analyses. Very fine equiaxed grains (<0.1um) with a low dislocation density were observed in the adiabatic shear bands (ASB) this enables a thermomechanical response that may lead to a super plastic de formation.

Size Effect on Onset and Subsequent Evolution of Adiabatic Shear Band:Theoretical and Numerical Analysis

The adiabatic shear instability of ductile materials has attracted more and more attentions of researchers and groups,who have been sparing no effort in further understanding of the underlying mechanism since the first experimental depiction of adiabatic shear instability by Zener and Hollomon.As for the adiabatic shear instability,many factors account for its occurrence,including heat conduction,inertia effect,microstructure effect and so on.However,lots of experimental evidence has shown that metal materials display a strong size effect when the characteristic length scale is in the order of microns.The size effect has also been observed in the analysis of shear band in the ductile materials because the order of the bandwidth stays within the microscale range.However,a comprehensive understanding of the whole process of adiabatic shear banding(ASB),including the early onset and the subsequent evolution,is still lacking.In this work,a gradient plasticity model based on the Taylor-based nonlocal theory feasible for the linear perturbation analysis and convenient for numerical calculation is proposed to investigate the strain gradient on the onset of ASB and the coupling effect of heat conduction,inertia effect and strain gradient at the early stage,as well as on the subsequent evolution process at later stages.As for the onset of ASB,the linear perturbation method is used to consider the effect on the initial formation of ASB.After the investigation of the onset of ASB.the characteristic line method is applied to describe the subsequent nonlinear evolution process of ASB.Three stages of ASB evolution are clearly depicted during the evolution process,and the significance of size effect on the ASB nonlinear evolution process of ASB at different stages is analyzed.With the help of linear perturbation analysis and characteristic line method,a comprehensive description of the role of strain gradient in the ASB from the early onset to the end of the evolution is provided.

Shear Band Formation in AISI 4340 Steel Under Dynamic Impact Loads:Modeling and Experiment

In this study, the occurrence of the adiabatic shear bands in AISI 4340 steel under high velocity impact loading was investigated using finite element analysis and experimental tests. The cylindrical specimen subjected to the impact load was divided into different regions separated by nodes using finite element method in ABAQUS environment with boundary conditions specified. The material properties were assumed to be lower in the region where the probability of strain localization is high based on prior experimental results in order to initialize the formation of the adiabatic shear bands. The finite element model was used to determine the maximum flow stress, the strain hardening, the thermal softening, and the time to reach the critical strain for the formation of adiabatic shear bands. Experimental results show that deformed bands were formed at low strain rates and there was a minimum strain rate required for the formation of the transformed band in the alloy and the cracks were initiated and propagated along the transformed bands leading to fragmentation under the impact loading. The susceptibility of the adiabatic shear bands to cracking was markedly influenced by the strain-rates and the initial material microstructure. The simulation results obtained were compared with the experimental results obtained from the AISI 4340 steel under high strain-rate loading in compression using split impact Hopkinson bars. A good agreement between the experimental and simulation results was obtained.

A NOVEL APPROACH TO TESTING THE DYNAMIC SHEAR RESPONSE OF Ti-6Al-4V

Modifications were made on the traditional split Hopkinson pressure bar （SHPB） system to conduct dynamic shear tests. The shear response of Ti-6A1-4V was acquired at a shear strain rate of 104 s-1 by using this modified apparatus. The geometry as well as the clamping mode of the double-notch specimen was optimized by commercial FEM software ABAQUS, and the feasibility of the experiment set-up was validated. A shear stress calibration coeff^cient of γT = 1.03 and a shear strain calibration coefficient of γT- = 0.50 were obtained.We have employed high- speed photography to record the deformation process, especially the initiation and propagation of adiabatic shear band （ASB）, during the dynamic shear test. The frames show that the time duration from ASB initiation to its completion is less than 2 μs, from which we can estimate that the propagation speed of ASB within Ti-6A1-4V is more than 1250 m/s under such loading conditions. The temperature rise within ASB is also estimated to be △T2 ≈ 1460 ℃ based on energy balance. Such high temperature has led to softening of the material within the ASBs, and has intensified the shear localization and finally resulted in fracture of the material.