Analytical and experimental study on formation of concentrated shear band of saw tooth chip in high-speed machining

Abstract

Saw tooth chip is a typical characteristic encountered in high-speed machining. It consists of nearly undeformed segments and highly sheared concentrated shear bands. However, no consensus on the formation of the concentrated shear band has been reached though several saw tooth chip formation models have been built. In this paper, the concentrated shear band formation procedure is analyzed based on a new proposed saw tooth chip formation model. Cutting experiments have been conducted to validate the proposed mode. It shows that the plastic side flow and elastic compression of the uncut chip are crucial for the concentrated shear band formation. The localized shear at the inner end (tool tip side) of the primary shear plane firstly takes place under the indentation of cutting tool. Then, the second localized shear is produced at the outer end (free surface side) of the primary shear plane due to stress concentration there, after which the whole concentrated shear band forms. The stress transition at the outer end of the primary shear plane makes the second localized shear easier evolve into cracks. Influences of material brittleness and cutting speed on initiation and propagation of the concentrated shear band are also analyzed.