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research-article

Study of the Shear Strain and Shear Strain Rate Progression during Titanium Machining

[+] Author and Article Information
Brian Davis

Department of Mechanical and Aerospace Engineering, University of Florida, Gainesville, FL 32611, USA
bdavis.18.bd@gmail.com

David Dabrow

Department of Mechanical and Aerospace Engineering, University of Florida, Gainesville, FL 32611, USA
daviddabrow@ufl.edu

Peter G. Ifju

Department of Mechanical and Aerospace Engineering, University of Florida, Gainesville, FL 32611, USA
ifju@ufl.edu

Guoxian Xiao

General Motors Global R&D, Warren, MI 48090, USA
guoxian.xiao@gm.com

Steven Y. Liang

George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332, USA
steven.liang@me.gatech.edu

Yong Huang

Department of Mechanical and Aerospace Engineering, University of Florida, Gainesville, FL 32611, USA; P.O.Box 116250, University of Florida, Gainesville, FL 32611, USA
yongh@ufl.edu

1Corresponding author.

ASME doi:10.1115/1.4038891 History: Received June 25, 2017; Revised December 01, 2017

Abstract

Machining is among the most versatile material removal processes in the manufacturing industry. To better optimize the machining process, the knowledge of shear strains and shear strain rates within the primary shear zone (PSZ) during chip formation has been of great interest. The objective of this study is to study the strain and strain rate progression within the PSZ both in the chip flow direction and along the thickness direction during machining equal channel angular extrusion (ECAE) processed titanium (Ti). ECAE-processed ultrafine-grained (UFG) Ti has been machined at cutting speeds of 0.1 and 0.5 m/s, and the shear strain and shear strain rate have been determined using high speed imaging and digital image correlation. It is found that the chip morphology is saw-tooth at 0.1 m/s while continuous at 0.5 m/s. The cumulative shear strain and incremental shear strain rate of the saw-tooth chip morphology can reach approximately 3.9 and 2.4×103 s-1, respectively, and those of the continuous chip morphology may be approximately 1.3 and 5.0×103 s-1, respectively. There is a distinct peak shift in the shear strain rate distribution during saw-tooth chip formation while there is a stable peak position of the strain rate distribution during continuous chip formation. The PSZ thickness during saw-tooth chip formation is more localized and smaller than that during continuous chip formation (28 versus 35 µm).

Copyright (c) 2017 by ASME
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