Research Papers

Mechanism of Chip Segmentation in Orthogonal Cutting of Zr-Based Bulk Metallic Glass

[+] Author and Article Information
Naresh Kumar Maroju

Department of Mechanical Engineering,
University of British Columbia,
2054-6250 Applied Science Lane,
Vancouver, BC, V6T 1Z4, Canada
e-mail: nareshkm@alumni.ubc.ca

Xiaoliang Jin

Department of Mechanical Engineering,
University of British Columbia,
2054-6250 Applied Science Lane,
Vancouver, BC, V6T 1Z4, Canada
e-mail: xjin@mech.ubc.ca

1Corresponding author.

Manuscript received March 12, 2019; final manuscript received May 16, 2019; published online June 10, 2019. Assoc. Editor: Radu Pavel.

J. Manuf. Sci. Eng 141(8), 081003 (Jun 10, 2019) (13 pages) Paper No: MANU-19-1144; doi: 10.1115/1.4043837 History: Received March 12, 2019; Accepted May 18, 2019

Bulk metallic glasses (BMGs) are a series of metal alloys with an amorphous structure. The deformation of BMGs occurs in localized regions and is highly sensitive to the applied stress, strain rate, and temperature. This paper presents a coupled thermomechanical model to analyze the chip segmentation mechanism due to material shear localization in orthogonal cutting of Zr-BMG. The shear stress variation in the primary shear zone is modeled considering the tool-chip friction and large strain of the material. The constitutive property of BMG corresponding to the inhomogeneous deformation through shear transformation zones is modeled. The oscillations of shear stress, temperature, and free volume are simulated based on the cutting conditions. The predicted chip segmentation frequency is compared with the experimental result under different cutting speeds and uncut chip thicknesses. The developed model provides the fundamental mechanism of material deformation and chip formation in cutting Zr-BMG with an amorphous structure.

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Fig. 1

Schematic representation of (a) segmented chip formation and (b) PSZ and velocity diagram

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Fig. 2

Kinematics of segmented chip formation

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Fig. 3

Numerical method to identify the stability of system

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Fig. 4

Comparison of analytical solution and numerical solution

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Fig. 5

Schematic representation of experimental setup

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Fig. 6

Variation of cutting force and thrust force with respect to uncut chip thickness

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Fig. 7

Strain rate sensitivity in orthogonal cutting of Zr-BMG

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Fig. 8

The predicted shear stress (τs), free volume (ζ), and temperature (T) with respect to cutting time for cutting speeds: (a) 1000 mm/min, (b) 700 mm/min, (c) 400 mm/min, and (d) 100 mm/min and 50 μm uncut chip thickness

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Fig. 9

The predicted shear stress (τs), free volume (ζ), and temperature (T) with respect to cutting time for uncut chip thickness: (a) 50 μm, (b) 40 μm, and (c) 30 μm at 100 mm/min

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Fig. 10

Segmented chip formation at (a) 1000 mm/min, (b) 700 mm/min, (c) 400 mm/min, and (d) 100 mm/min and 50 μm uncut chip thickness

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Fig. 11

Segmented chip formation at uncut chip thickness (a) 30 µm, (b) 40 µm, and (c) 50 µm at 100 mm/min

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Fig. 12

Instability index of dimensionless free volume and temperature with dimensionless time

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Fig. 13

Variation of shear stress (τs), free volume (ζ), and temperature (T) (a) include the thermal effect and (b) assume constant temperature

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Fig. 14

Comparison of XRD spectrums of the as-received BMG and machined chip at 1000 mm/min cutting speed and 50 µm uncut chip thickness

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Fig. 15

Comparison of shear stresses at various cutting speeds and 50 μm uncut chip thickness



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