NOTICE: Due to a lapse in annual appropriations, most of this website is not being updated. Learn more.
Form submissions will still be accepted but will not receive responses at this time. Sections of this site for programs using non-appropriated funds (such as NVLAP) or those that are excepted from the shutdown (such as CHIPS and NVD) will continue to be updated.
An official website of the United States government
Here’s how you know
Official websites use .gov
A .gov website belongs to an official government organization in the United States.
Secure .gov websites use HTTPS
A lock (
) or https:// means you’ve safely connected to the .gov website. Share sensitive information only on official, secure websites.
Serrated Chip Morphology and Comparison with Finite Element Simulations
Published
Author(s)
Laurent Deshayes, Robert W. Ivester, T Mabrouki, J F. Rigal
Abstract
The complexity of chip formation in machining processes stems from the confluence of several physical phenomena - mechanical, thermal, and chemical - occurring at very high strain rate. The prediction of chip morphology depends on a fundamental understanding of these phenomena and is of industrial importance for cutting force prediction and surface integrity control. Within this framework, our paper focuses on the modelling of serrated-chip formation (saw-tooth shape chip) and on the physical phenomena accompanying the serrated-chip formation according to the variation of feed rate. In the first part, bibliography review and experimental study on chip formation is made. The experimental study, based on metallographic analysis of chip morphology, foceses on the machining of an American Iron and Steel Institute (AISI) 4340 steel alloy work material. The second part of the paper deals with the FEM model to simulate cutting processes using the Abaque explicit code and Third Wave Systems Advantedge software. The simulation utilize plasticity models for material behavior and damage to predict chip morphology. The third section proposes a comparison of simulations results with experimental observations. Experimental results support the results of the simulations for various cutting parameters. We end the paper with some concluding remarks.
Conference Dates
November 13-19, 2004
Conference Location
Anaheim, CA, USA
Conference Title
ASME International Mechanical Engineering Congress & Exposition
Pub Type
Conferences
Keywords
finite element simulations, metal cutting, serrated chip, shear band hardness
Deshayes, L.
, Ivester, R.
, Mabrouki, T.
and Rigal, J.
(2004),
Serrated Chip Morphology and Comparison with Finite Element Simulations, ASME International Mechanical Engineering Congress & Exposition, Anaheim, CA, USA
(Accessed October 11, 2025)