Time-Varying Tool-Chip Contact in the Cutting Mechanics of Shear Localization

IF 2.4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING
M. Fazlali, Xiaoliang Jin
{"title":"Time-Varying Tool-Chip Contact in the Cutting Mechanics of Shear Localization","authors":"M. Fazlali, Xiaoliang Jin","doi":"10.1115/1.4062749","DOIUrl":null,"url":null,"abstract":"\n Shear localization is the dominant chip formation mechanism in machining of high performance metallic components, such as those made of titanium and nickel-based alloys. This paper presents an analytical thermo-mechanical model considering a new tool-chip contact mechanism due to shear localization. First, it is experimentally shown that the sticking and sliding contact lengths fluctuate with the frequency of shear localization. Second, a cutting mechanics model is developed considering the shear band formation, its rolling on the tool’s rake face, and the time-varying tool-chip contact length with experimental validation. Finally, the transient temperature at the tool-chip interface is predicted by taking the rolling phenomenon and the time-varying heat sources at the tool-chip interface into account. The proposed model shows that at the beginning of each segmentation cycle, the entire tool-chip contact length is dominated by sliding condition with negligible sticking length. When the tool advances, new workpiece material piles up in its front with an increase in the sticking length. Meanwhile, the sliding length decreases due to the drop in the load-bearing capacity of the shear band. When enough material piles up in front of the tool, a new shear band forms, and the entire contact length returns to the sliding condition. This process repeats each time a shear band occurs, causing the cyclic formation of shear bands and time-varying nature of the tool-chip contact length, therefore influencing the temperature and stress evolution at the tool-chip interface.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":2.4000,"publicationDate":"2023-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Manufacturing Science and Engineering-transactions of The Asme","FirstCategoryId":"5","ListUrlMain":"https://doi.org/10.1115/1.4062749","RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}
引用次数: 0

Abstract

Shear localization is the dominant chip formation mechanism in machining of high performance metallic components, such as those made of titanium and nickel-based alloys. This paper presents an analytical thermo-mechanical model considering a new tool-chip contact mechanism due to shear localization. First, it is experimentally shown that the sticking and sliding contact lengths fluctuate with the frequency of shear localization. Second, a cutting mechanics model is developed considering the shear band formation, its rolling on the tool’s rake face, and the time-varying tool-chip contact length with experimental validation. Finally, the transient temperature at the tool-chip interface is predicted by taking the rolling phenomenon and the time-varying heat sources at the tool-chip interface into account. The proposed model shows that at the beginning of each segmentation cycle, the entire tool-chip contact length is dominated by sliding condition with negligible sticking length. When the tool advances, new workpiece material piles up in its front with an increase in the sticking length. Meanwhile, the sliding length decreases due to the drop in the load-bearing capacity of the shear band. When enough material piles up in front of the tool, a new shear band forms, and the entire contact length returns to the sliding condition. This process repeats each time a shear band occurs, causing the cyclic formation of shear bands and time-varying nature of the tool-chip contact length, therefore influencing the temperature and stress evolution at the tool-chip interface.
剪切局部化切削力学中的时变刀屑接触
剪切局部化是加工高性能金属部件(如钛和镍基合金制成的部件)的主要切屑形成机制。本文提出了一个考虑剪切局部化引起的新型刀具-芯片接触机制的热机械分析模型。首先,实验表明,粘滑接触长度随剪切局部化频率的变化而变化。其次,建立了考虑剪切带形成、剪切带在刀具前刀面上的滚动以及时变刀具-切屑接触长度的切削力学模型,并进行了实验验证。最后,通过考虑滚动现象和工具-芯片界面处的时变热源,预测了工具-芯片接口处的瞬态温度。所提出的模型表明,在每个分割周期开始时,整个刀具-芯片接触长度由滑动条件主导,粘着长度可以忽略不计。当刀具前进时,随着粘着长度的增加,新的工件材料会堆积在刀具的前部。同时,由于剪切带承载能力的下降,滑动长度减小。当足够多的材料堆积在工具前面时,就会形成一个新的剪切带,整个接触长度就会恢复到滑动状态。每次出现剪切带时,该过程都会重复,导致剪切带的循环形成和工具-芯片接触长度的时变性质,从而影响工具-芯片界面的温度和应力演变。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
求助全文
约1分钟内获得全文 求助全文
来源期刊
CiteScore
6.80
自引率
20.00%
发文量
126
审稿时长
12 months
期刊介绍: Areas of interest including, but not limited to: Additive manufacturing; Advanced materials and processing; Assembly; Biomedical manufacturing; Bulk deformation processes (e.g., extrusion, forging, wire drawing, etc.); CAD/CAM/CAE; Computer-integrated manufacturing; Control and automation; Cyber-physical systems in manufacturing; Data science-enhanced manufacturing; Design for manufacturing; Electrical and electrochemical machining; Grinding and abrasive processes; Injection molding and other polymer fabrication processes; Inspection and quality control; Laser processes; Machine tool dynamics; Machining processes; Materials handling; Metrology; Micro- and nano-machining and processing; Modeling and simulation; Nontraditional manufacturing processes; Plant engineering and maintenance; Powder processing; Precision and ultra-precision machining; Process engineering; Process planning; Production systems optimization; Rapid prototyping and solid freeform fabrication; Robotics and flexible tooling; Sensing, monitoring, and diagnostics; Sheet and tube metal forming; Sustainable manufacturing; Tribology in manufacturing; Welding and joining
×
引用
GB/T 7714-2015
复制
MLA
复制
APA
复制
导出至
BibTeX EndNote RefMan NoteFirst NoteExpress
×
提示
您的信息不完整,为了账户安全,请先补充。
现在去补充
×
提示
您因"违规操作"
具体请查看互助需知
我知道了
×
提示
确定
请完成安全验证×
copy
已复制链接
快去分享给好友吧!
我知道了
右上角分享
点击右上角分享
0
联系我们:info@booksci.cn Book学术提供免费学术资源搜索服务,方便国内外学者检索中英文文献。致力于提供最便捷和优质的服务体验。 Copyright © 2023 布克学术 All rights reserved.
京ICP备2023020795号-1
ghs 京公网安备 11010802042870号
Book学术文献互助
Book学术文献互助群
群 号:481959085
Book学术官方微信