Abstract
We examine segmented chip formation and associated flow dynamics in cutting of metals of low-to-moderate workability using high-speed imaging. Segmentation is initiated by a surface instability – formation of a ductile crack in a prow – on workpiece surface ahead of the tool, this crack then propagates towards the tool tip. Prow-crack initiation occurs at a critical strain ˜0.75 that is independent of material and deformation geometry. This ductile failure is analyzed in terms of local hydrostatic stress state and stress triaxiality. Material-agnostic methods to suppress and enhance segmentation using constrained cutting and a mechanochemical effect are demonstrated.
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