Chip formation mechanism in milling metallic glasses based on Drucker-Prager (D-P) constitutive model

Abstract

In this paper, further in-depth research on chip formation mechanism is conducted on the cutting of metallic glasses. The study of chips contributes to a better understanding of the machining nature of materials, which is of significant importance for improving product quality, reducing energy consumption, and resource utilization. This paper employs a combination of simulation and experimental methods, wihch not only analyzes the mechanism of chip formation in depth, but also investigates the time-varying characteristics of cutting forces. The results indicate that, when comparing simulation with experiments, the average error in cutting forces is 7.62%, and the chip morphology is also quite similar. Observations in the simulation show that as the cutting thickness increases from 7.96 μm to 23.87 μm, the free surface of the chip exhibits serrated features, and the main shear zone of the chip becomes clearer. Cutting forces exhibit periodic variations, with alternating peaks and valleys representing the formation of shear zones in the chip. In the experiment, observed chips displays a wrinkled free surface and a smooth non-free surface, with some chip edges exhibiting a burr phenomenon. By selecting appropriate machining parameters, the generation of secondary shear bands on the free surface was effectively reduced. By observing the chip morphology, it is found that the chip formation is accompanied by the material removal of plasticity and brittleness, which is the result of the combined action of heat, stress, and free volume. It should be considered to lower temperature to reduce the phenomenon of chip adhesion, providing guidance for further optimizing the cutting process of metallic glass. This paper can provide to readers further understanding of the chip formation mechanism in milling metal glass.