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Sinuous flow in metals.

Ho Yeung1, Koushik Viswanathan1, Walter Dale Compton1

  • 1Center for Materials Processing and Tribology, School of Industrial Engineering, Purdue University, West Lafayette, IN 47907.

Proceedings of the National Academy of Sciences of the United States of America
|July 29, 2015
PubMed
Summary
This summary is machine-generated.

Cutting annealed metals is difficult due to high forces and thick chips. This study reveals it

Keywords:
deformationfoldinginstabilitymetal cuttingplasticity

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Area of Science:

  • Materials Science and Engineering
  • Mechanical Engineering
  • Physics of Materials

Background:

  • Annealed metals present challenges in machining, characterized by high cutting forces and thick chips.
  • Previous models, based on ex situ observations, explained this anomaly using smooth plastic flow and uniform shear.
  • These models failed to capture the underlying mechanism of material removal during chip formation.

Purpose of the Study:

  • To investigate the fundamental mechanism behind the high cutting forces and thick chip formation in annealed metals.
  • To challenge the existing models of material removal and propose a new deformation mode.
  • To explore methods for reducing cutting forces by manipulating the observed deformation mechanism.

Main Methods:

  • Utilized in situ imaging techniques to observe chip formation in real-time during metal cutting.
  • Analyzed the collective deformation modes and material flow patterns at the microscale.
  • Experimentally manipulated surface conditions to investigate their effect on chip formation and cutting forces.

Main Results:

  • Identified a novel collective deformation mode termed 'sinuous flow' as the cause of chip formation.
  • Demonstrated that sinuous flow is triggered by surface undulations of a characteristic size, leading to large-amplitude folding.
  • Showed that suppressing surface undulations (e.g., using marking ink or surface prehardening) drastically reduces cutting forces.

Conclusions:

  • Sinuous flow is a distinct mesoscopic deformation mode in metals, comparable to kinking and shear banding.
  • The cutting anomaly in annealed metals is explained by this sinuous flow mechanism, not smooth plastic flow.
  • Controlling surface topography offers a direct pathway to reduce machining forces and improve industrial processes.