Journal
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
Volume 86, Issue -, Pages 18-33Publisher
ELSEVIER SCI LTD
DOI: 10.1016/j.ijmachtools.2014.06.006
Keywords
High speed machining; Serrated chip flow; Dimensional analysis; Shear banding
Funding
- Nature Science Foundation of China [11132011, 11202221]
- National Basic Research Program of China [2012CB937500]
- China Postdoctoral Science Foundation [2013M540148]
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The transition of continuously smooth chip flow to periodically serrated chip flow as the cutting speed increasing is one of the most fundamental and challenging problems in high speed machining. Here, an explicit expression of the critical cutting speed for the onset of serrated chip flow, which is given in terms of material properties, uncut chip thickness and tool rake angle, is achieved based on dimensional analysis and numerical simulations. It could give reasonable predictions of the critical cutting speeds at which chips change from continuous to serrated for various metallic materials over wide ranges of uncut chip thickness and tool rake angle. More interestingly, it is found that, as the turbulent flow is controlled by the Reynolds number, the transition of the serrated chip flow mode is dominated by a Reynolds thermal number. Furthermore, the influences of material properties on the emergence of serrated chip flow are systematically investigated, the trends of which show good agreement with Recht's classical model. (C) 2014 Elsevier Ltd. All rights reserved.
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