On the chip formation process of a Zr-based bulk metallic glass: A systematic study

Abstract

Zirconium-based bulk metallic glasses (BMGs) show significant challenges in machining for their excellent mechanical properties. In order to gain a comprehensive understanding of the BMGs machining, it is important to study the chip formation process. Firstly, the von Mises equivalent stress, temperature, equivalent plastic strain, and strain rate during the chip formation process were analyzed through finite element simulations (FEM). Subsequently, this study investigated the chip morphology of the BMGs. Energy dissipation analysis revealed that the energy consumed in serration formation process increased with increasing cutting speed, feed rate, and cutting depth. Finally, the Weibull distribution model was utilized to analyze the stability of the adiabatic shear band spacing under different cutting speeds. The results indicated that a lower cutting speed led to more stable chip formation and better surface quality. The present findings provide a theoretical basis for optimizing machining quality and enhancing surface performance of Zr-based BMGs.