Simulation analysis of the influence of dynamic flow stress behavior on chip formation

Abstract

The reliability and accuracy of finite element models of metal machining are heavily reliant on the underlying material flow stress models. The aim of this study is to characterize the relation between the flow stress models and the chip morphology to provide a deeper insight into the process of serrated chip formation. Firstly, in the context of a flow stress model, the critical conditions for generation of the serrated chips are theoretically analyzed. Then, simulations are performed using two different constitutive models with five parameters sets, and the results are discussed in relation to how they verify the theoretical results. In order to better understand the process of serrated chip formation, attention is concentrated on the critical steps characterizing the formation of a single chip segment. The cutting process parameters (stress, strain, and temperature) are discussed. In addition, the mechanism by which the chip morphology transforms from continuous to serrated with increasing cutting speed is investigated in terms of the variation of flow stress curves. The results show that the slope of decrease and the strain value at the peak point of flow stress curves both greatly affect chip morphology. That is, the slope of decrease of the flow stress curve largely controls the formation of serrated chips, while the strain point at the peak determines the frequency and degree of serration of chips. It is found that simulations by manipulating well the flow stress models can produce results for chip morphology, cutting forces, etc. that are closer to those obtained experimentally.