Title: Experimental research of chip formation mechanism during high speed machining of hardened steel

Authors: Chunzheng Duan, Tao Tou, Minjie Wang

Addresses: School of Mechanical Engineering, Key Laboratory of Ministry of Education for Precision and Non-traditional Machining, Dalian University of Technology, Dalian 116023, China. ' School of Mechanical Engineering, Key Laboratory of Ministry of Education for Precision and Non-traditional Machining, Dalian University of Technology, Dalian 116023, China. ' School of Mechanical Engineering, Key Laboratory of Ministry of Education for Precision and Non-traditional Machining, Dalian University of Technology, Dalian 116023, China

Abstract: The development of chip morphology, critical cutting conditions of serrated chip formation and cutting forces were observed and measured by high speed machining experiment for 30CrNi3MoV hardened steel. Results show that the cutting speed and rake angle are leading factors to influence chip morphology and cutting forces. With the increase of cutting speed, the continuous band chip transforms into serrated chip at a certain critical value. As the rake angle is changed from positive to negative, the critical cutting speed significantly decreases, the cutting forces abruptly reduces when the serrated chip forms. The results from predicting critical cutting speed using the critical cutting condition criterion of adiabatic shear in metal cutting process show that the leading reason of serrated chip formation is that the adiabatic shear fracture repeatedly occurs in the primary shear zone.

Keywords: high speed machining; chip formation mechanisms; serrated chips; adiabatic shear; cutting force; computer aided engineering; CAE; hardened steel; chip morphology; rake angle; cutting speed; metal cutting.

DOI: 10.1504/IJCAET.2011.042355

International Journal of Computer Aided Engineering and Technology, 2011 Vol.3 No.5/6, pp.458 - 465

Published online: 06 Sep 2011 *

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