Abstract
We characterize primary (shape-change) and secondary (friction) deformation, and associated temperature fields, in metal cutting and forming processes, using in situ imaging and simulation. The experimental configurations enable access to the deformation zones and die contact interfaces, for measuring deformation, temperature, and frictional drag. Infrared thermography reveals that the plastic strain-rate field is an excellent proxy for the deformation-induced heat sources. Both spatially confined and diffuse strain-rate fields occur, depending on the initial workpiece deformation state. When the strain rate is confined, as in prehardened material, the temperature modeling is greatly simplified, as the heat source is also now localized. However complex, microstructure-driven deformation modes, such as sinuous flow in annealed metals, result in spatially diffuse strain-rate and body heat sources that are more challenging to analyze. Our unified measurements should be of value for accurately estimating the fraction of plastic dissipation that is converted into heat in large-strain deformation processes.
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