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Adiabatic shear mechanisms for the hard cutting process

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Abstract

The most important consequence of adiabatic shear phenomenon is formation of sawtooth chip. Lots of scholars focused on the formation mechanism of sawtooth, and the research often depended on experimental approach. For the present, the mechanism of sawtooth chip formation still remains some ambiguous aspects. This study develops a combined numerical and experimental approach to get deeper understanding of sawtooth chip formation mechanism for Polycrystalline Cubic Boron Nitride (PCBN) tools orthogonal cutting hard steel GCr15. By adopting the Johnson-Cook material constitutive equations, the FEM simulation model established in this research effectively overcomes serious element distortions and cell singularity in high strain domain caused by large material deformation, and the adiabatic shear phenomenon is simulated successfully. Both the formation mechanism and process of sawtooth are simulated. Also, the change features regarding the cutting force as well as its effects on temperature are studied. More specifically, the contact of sawtooth formation frequency with cutting force fluctuation frequency is established. The cutting force and effect of cutting temperature on mechanism of adiabatic shear are investigated. Furthermore, the effects of the cutting condition on sawtooth chip formation are researched. The researching results show that cutting feed has the most important effect on sawtooth chip formation compared with cutting depth and speed. This research contributes a better understanding of mechanism, feature of chip formation in hard turning process, and supplies theoretical basis for the optimization of hard cutting process parameters.

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Authors and Affiliations

  1. State Engineering Laboratory of High Efficiency Cutting and Tool, Harbin University of Science and Technology, Harbin, 150080, China

    Caixu Yue, Bo Wang, Xianli Liu, Huize Feng & Chunbin Cai

Authors
  1. Caixu Yue
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  2. Bo Wang
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  3. Xianli Liu
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  4. Huize Feng
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  5. Chunbin Cai
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Corresponding author

Correspondence to Caixu Yue.

Additional information

Supported by National Natural Science Foundation of China (Grant Nos. 51105119, 51235003)

YUE Caixu, born in 1982, associate professor. He received his doctor degree on machinery manufacture from Harbin University of Science and Technology, China, in 2013. His research interests include hard cutting mechanics and control of cutting process.

WANG Bo, born in 1964. She is a PhD candidate at Harbin University of Science and Technology, China. Her research interest includes cutting mechanics of free-form surfaces.

LIU Xianli, born in 1961, a PhD supervisor, is a professor at Harbin University of Science and Technology, China. He received his doctor degree on machinery manufacture from Harbin Institute of Technology, China, in 1999.

FENG Huize, born in 1985. He is a master candidate at Harbin University of Science and Technology, China. His research interest is hard cutting mechanics of free-form surfaces.

CAI Chunbin, born in 1989. He is a master candidate at Harbin University of Science and Technology, China. His research interest is finite element simulation technology of hard cutting process.

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Yue, C., Wang, B., Liu, X. et al. Adiabatic shear mechanisms for the hard cutting process. Chin. J. Mech. Eng. 28, 592–598 (2015). https://doi.org/10.3901/CJME.2015.0311.028

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  • DOI: https://doi.org/10.3901/CJME.2015.0311.028

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