Evaluation of Chip Morphology in Hard Turning Using Constitutive Models and Material Property Data

[+] Author and Article Information
Gérard Poulachon

 ENSAM, LaBoMaP, 71250 Cluny, Francegerard.poulachon@cluny.ensam.fr

Alphonse L. Moisan

 ENSAM, LaBoMaP, 71250 Cluny, Francealphonse.moisan@aix.ensam.fr

I. S. Jawahir

Machining Research Laboratory, 414C CRMS,  University of Kentucky, Lexington, KY 40506-0108jawahir@engr.uky.edu

J. Manuf. Sci. Eng 129(1), 41-47 (Mar 27, 2006) (7 pages) doi:10.1115/1.2335850 History: Received August 22, 2003; Revised March 27, 2006

Modeling of machining operations requires the use of constitutive relations which could represent as close as possible the material behavior in the primary and secondary zones. The knowledge of these behavior laws involves the use of different types of sophisticated mechanical tests which should provide with sufficient accuracy the material behavior for the relevant conditions of machining. In this paper, first, the flow stress of 100Cr6 (AISI 52100) bearing steel in its HV730 hardness state has been identified in order to assess the machinability in case of hard turning. With this, the dependence of the flow stress on strain, strain rate and temperature, which poses significant difficulty, is presented. Second, the material machinability is evaluated with a shear instability criterion, enabling the prediction of chip formation with or without the shear localization. Quick-stop tests have been carried out on the bearing steel treated at different hardness values showing the chip formation variation. Micro-hardness tests performed on these quick-stop test samples show the effects of cutting temperature. A greater understanding of applied machinability is gained through this precise study of work material physical properties and behavior.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

Strain-rate range reached in metalworking and limitations of the standard mechanical tests

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Figure 2

Impact energy and toughness according to hardness

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Figure 3

Hot compression tests and thermal softening

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Figure 4

Thermo-mechanical decoupling

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Figure 5

Sawtooth chip formation at various cutting speeds (Vc:m∕min, f=0.1mm∕rev, ap=1mm)

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Figure 6

Sawtooth chip at various feeds (f:mm∕rev, Vc=100m∕min, ap=1mm)

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Figure 7

Quick-stop tests and micro-hardness measurements (Vc=100m∕min, f=0.1mm∕rev, ap=1mm)

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Figure 8

Instability criterion according to Vc, f, T, γ¯



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