Finite element simulation of segmented chip formation of Ti6Al4V

The mechanism behind chip segmentation of titanium alloys is still unclear. Experimentally, different kinds of deformation patterns are observed. In this paper we perform a finite element analysis where chip segmentation is done by introducing cracks from the chip surface into the material. A fine mesh is used within the segments, allowing a high resolution of the occurring strain gradients. Because of stress concentration at the crack tip, adiabatic shear bands can form and lead to a strongly segmented chip with pronounced deformation in the crack region. Depending on the cracking parameters, different deformation patterns at the crack flanks are observed.