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Cutting Depth Dictates the Transition from Continuous to Segmented Chip Formation.

Ramin Aghababaei1,2, Mohammad Malekan1,3, Michal Budzik1,2

  • 1Department of Mechanical and Production Engineering, Aarhus University, 8000 Aarhus C, Denmark.

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Summary
This summary is machine-generated.

This study unifies material cutting mechanisms, showing a critical depth of cut determines chip formation via plastic deformation or fracture. This framework reconciles distinct cutting behaviors for better process control.

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Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Manufacturing Processes

Background:

  • Material cutting involves complex nonlinear phenomena like friction, plastic deformation, and fracture.
  • Achieving smooth material removal and high-quality surface finish requires understanding shear deformation.
  • Preventing long chip formation necessitates controlling fracture-induced chip breaking.

Purpose of the Study:

  • To reconcile discrepant observations and predictions of distinct material cutting mechanisms.
  • To develop a unified framework for understanding chip formation.
  • To establish a predictive model for chip formation based on material properties, tool geometry, and process parameters.

Main Methods:

  • Development of a simple analytical model to predict chip formation mechanisms.
  • In situ orthogonal cutting experiments for validation.
  • Analysis of literature data across a wide range of materials and length scales.

Main Results:

  • A unified framework is established, reconciling plastic deformation and fracture-induced chip breaking.
  • A critical depth of cut is identified, determining the dominant chip formation mechanism.
  • Below the critical depth, gradual plastic deformation occurs; above it, abrupt crack propagation leads to chip breaking.

Conclusions:

  • The developed analytical model accurately predicts chip formation mechanisms.
  • The findings provide a basis for optimizing cutting processes for desired outcomes.
  • The unified framework enhances understanding of material removal processes across various scales.