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Research Papers

Chip Flow and Scaling Laws in High Speed Metal Cutting

[+] Author and Article Information
Guy Sutter1

Laboratoire de Physique et Mécanique des Matériaux,  Université Paul Verlaine -Metz Ile du Saulcy, 57045 Metz Cedex 01, Francesutter@lpmm.univ-metz.fr

Alain Molinari

Laboratoire de Physique et Mécanique des Matériaux,  Université Paul Verlaine -Metz Ile du Saulcy, 57045 Metz Cedex 01, Francealain.molinari@univ-metz.fr

Gautier List

Laboratoire de Physique et Mécanique des Matériaux,  Université Paul Verlaine -Metz Ile du Saulcy, 57045 Metz Cedex 01, Francegautier.list@univ-metz.fr

Xuefeng Bi

Shanghai-Hamburg College,  University of Shanghai for Science and Technology, 200093 Shanghai, Chinaxuefeng.bi@gmail.com

1

Corresponding author.

J. Manuf. Sci. Eng 134(2), 021005 (Apr 04, 2012) (9 pages) doi:10.1115/1.4005793 History: Received June 17, 2010; Revised December 09, 2011; Published March 30, 2012; Online April 04, 2012

Chip formation in machining plays an important role in the cutting process optimisation. Chip morphology often reflects the choice of cutting conditions, the tool wear and by consequences the integrity of the machined surface and tool life. In this study, photographs of the chip morphology during high speed machining of a middle hard steel (C20 similar to AISI 1020) are taken by using a ballistic setup. From these recordings, the evolution of the chip morphology is presented and analysed in terms of cutting conditions. A simplified modeling is then proposed by considering the workpiece material as elastic perfectly plastic. The existence of a scaling law governing the chip morphology in high speed machining is demonstrated. The cutting velocity is shown to have a weak effect at high speed machining as opposed to the well known strong influence of the velocity in the range of low cutting speeds.

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Copyright © 2012 by American Society of Mechanical Engineers
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References

Figures

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Figure 2

Different stages of the chip formation in orthogonal cutting. No contact (a) or contact (b) of the chip with the workpiece. Effect of the chip breaker (c).

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Figure 3

Diagram of the ballistic setup

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Figure 4

Real time photographs of chip formation—evolution of the radius of curvature R (mm) along the chip (a) contactless: V = 17 m/s; t1  = 0.30 mm (stage I), (b) contact with the workpiece: V = 25 m/s; t1  = 0.09 mm (stage II).

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Figure 5

Mean normalized radius of curvature R¯/t1 of the chip with respect to the uncut chip thickness for two values of the cutting speed

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Figure 6

Illustration of a chip with a high radius of curvature obtained with a small depth of cut. V = 25 m/s; t1  = 0.04 mm; R¯ = 1.54 mm; Lc  = 0.44 mm.

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Figure 7

Normalized contact length as function of the uncut chip thickness for two cutting speeds

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Figure 8

Evolution of the chip thickness t2 as function of the uncut chip thickness t1 for two cutting speeds

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Figure 9

Geometrical parameters of the modeling

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Figure 10

Configuration P and P̃ related by the homothetic ratio β̃. Two homologous points M and M̃ are related by: ÃM̃¯=β̃AM¯ or x̃¯=β̃x¯.

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Figure 11

Various pictures used to validate the homothetic correspondence between various chip geometries

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Figure 1

Schematic view of the orthogonal cutting process

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