This paper presents comparisons between finite element modeling and experimental measurement of chip segmentation in American Iron and Steel Institute 1045 Steel. Direct measurements of chip segmentation through post-process microscopic analysis or indirect observations of secondary phenomena such as acoustic emissions provide limited insight into chip formation. This paper presents measurements based on high-speed microvideography of orthogonal disk cutting, which provides direct spatial and temporal observation of dynamic chip formation mechanisms. The results show that segment spacing grows nearly linearly with surface speed. Finite element modeling (FEM) simulations provide a physics-based mechanism for exploring the effectiveness of proposed mechanisms for explaining changes in fundamental cutting behavior with processing conditions. The FEM simulations yielded higher average segmentation frequencies with lower variability than the experiments, but they did agree with the range of experimental variation.
Conference Dates: August 27-28, 2007
Conference Location: Reggio Calabria, IT
Conference Title: 10th CIRP International Workshop on Modeling of Machining Operations
Pub Type: Conferences
chip morphology, high-speed video, orthogonal cutting, segmentation