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Research Papers

Unified Criterion for Brittle–Ductile Transition in Mechanical Microcutting of Brittle Materials

[+] Author and Article Information
X. Cheng, X. T. Wei, X. H. Yang

School of Mechanical Engineering,
Shandong University of Technology,
Zibo 255049, China

Y. B. Guo

Department of Mechanical Engineering,
The University of Alabama,
Tuscaloosa, AL 35487
e-mail: yguo@eng.ua.edu

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received January 1, 2014; final manuscript received June 28, 2014; published online August 6, 2014. Assoc. Editor: Donggang Yao.

J. Manuf. Sci. Eng 136(5), 051013 (Aug 06, 2014) (7 pages) Paper No: MANU-14-1002; doi: 10.1115/1.4027996 History: Received January 01, 2014; Revised June 28, 2014

Various brittle–ductile transition (BDT) criteria have been developed in the literature to estimate the critical conditions for ductile microcutting of brittle materials. This study provides a unified criterion to efficiently and accurately estimate the critical condition based on the indentation model on brittle materials. The unified criterion correlates with the cutting edge radius, material properties, and a dimensionless coefficient fitted by the experimental data. It shows that the cutting edge geometry is the dominant factor and the maximum undeformed chip thickness (MUCT) can be used as the unified criterion in BDTs. Based on the proposed model, microturning and micromilling have been analyzed to determine the threshold value of the MUCT for ductile microcutting. The model has been validated by the experimental data. Based on the models and three-dimensional geometrical model of microcutting, a further analysis shows that the process conditions greatly affect the microcutting efficiency even though all the conditions may achieve the ductile-regime cutting.

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References

Figures

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Fig. 1

Geometrical model of microturning

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Fig. 2

Definition of UCT (h) in microturning

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Fig. 3

Geometrical model of micromilling

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Fig. 4

Projected views of the radial and axial cutting actions

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Fig. 5

Definition of UCT (h) in micromilling

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Fig. 6

Tip of the Vickers indenter

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Fig. 7

Micro cutting process in an orthogonal view

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Fig. 8

Schematic view of the axial cutting action in micromilling

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Fig. 12

Efficiency comparison of micromilling

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Fig. 11

Efficiency comparison of microturning

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Fig. 10

Model predictions versus experimental data

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Fig. 9

The fitted dimensionless coefficient versus cutting edge radius

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