Research Paper:
Investigation of the Influence of Built-Up Layer on the Stress State in the Primary Shear Zone Using Particle Image Velocimetry Analysis
Xiaoqi Song*, , Kenji Suzuki* , Weiming He**, and Tohru Ihara***
*Department of Mechanical Systems Engineering, School of Engineering, Kogakuin University
2665-1 Nakano-machi, Hachioji, Tokyo 192-0015, Japan
Corresponding author
**School of Mechanical Engineering, University of Shanghai for Science and Technology
Shanghai, China
***Department of Precision Mechanics, Chuo University
Tokyo, Japan
In this study, a novel methodology was proposed to investigate the influence of the built-up layer (BUL) formation on the stress state distribution in the primary shear zone (PSZ) using analytical model and particle image velocimetry (PIV) analysis. Orthogonal cutting tests were performed under a range of uncut chip thicknesses and cutting speeds using two uncoated cemented carbide tools with different rake angles. A series of shear strain, shear strain rate, and velocity distributions in PSZ were obtained by PIV analysis. Al7075-T6511 was used as the workpiece. Subsequently, the influences of cutting conditions on the BUL/built-up edge (BUE) formation and the plastic deformation in PSZ were investigated. Using these results, the parameters of the proposed analytical model were identified, and the influences of the BUL/BUE formation on the stress state distribution were investigated. From the experimental results, it was found that in the cutting speed range below 2 m/min, only BUE is formed, and the uncut chip thickness and tool rake angle have a significant influence on its formation. The agreement between the measured and calculated results demonstrated the effectiveness of the proposed methodology. The results confirmed that the BUE formation has little effect on the bell-shaped distribution of shear strain rate, but has a significant influence on the thickness of PSZ, chip sliding velocity near the outlet boundary of PSZ, maximum shear strain rate, stress state, and temperature in PSZ. It was also confirmed that the stress triaxiality plays an important role in the BUE formation. These results provide a deeper understanding of the BUL/BUE formation.
- [1] X. Song, Y. Takahashi, W. He, and T. Ihara, “Study on the protective effect of built-up layer in dry cutting of stainless steel SUS304,” Precision Engineering, Vol.65, pp. 138-148, 2020. https://doi.org/10.1016/j.precisioneng.2020.05.010
- [2] E. Uhlmann, S. Henze, K. Brömmelhoff, and W. Reimers, “Cutting simulation with consideration of the material hardening in the shear zone of AISI1045,” Procedia CIRP, Vol.58, pp. 91-96, 2017. https://doi.org/10.1016/j.procir.2017.03.199
- [3] X. Jin and Y. Altintas, “Slip-line field model of micro-cutting process with round tool edge effect,” J. of Materials Processing Technology, Vol.211, No.3, pp. 339-355, 2011. https://doi.org/10.1016/j.jmatprotec.2010.10.006
- [4] T. H. C. Childs, “Ductile shear failure damage modelling and predicting built-up edge in steel machining,” J. of Materials Processing Technology, Vol.213, No.11, pp. 1954-1969, 2013. https://doi.org/10.1016/j.jmatprotec.2013.05.017
- [5] D. Zhang, X.-M. Zhang, G.-C. Nie, Z.-Y. Yang, and H. Ding, “In situ imaging based thermo-mechanical analysis of built-up edge in cutting process,” J. of Manufacturing Processes, Vol.71, pp. 450-460, 2021. https://doi.org/10.1016/j.jmapro.2021.09.040
- [6] W. Thielicke and R. Sonntag, “Particle image velocimetry for MATLAB: Accuracy and enhanced algorithms in PIVlab,” J. of Open Research Software, Vol.9, No.1, 12, 2021. https://doi.org/10.5334/jors.334
- [7] W. Thielicke and E. J. Stamhuis, “PIVlab – Towards user-friendly, affordable and accurate digital particle image velocimetry in MATLAB,” J. of Open Research Software, Vol.2, No.1, e30, 2014. https://doi.org/10.5334/jors.bl
- [8] V. P. Astakhov, M. O. M. Osman, and M. T. Hayajneh, “Re-evaluation of the basic mechanics of orthogonal metal cutting: Velocity diagram, virtual work equation and upper-bound theorem,” Int. J. of Machine Tools and Manufacture, Vol.41, No.3, pp. 393-418, 2001. https://doi.org/10.1016/S0890-6955(00)00084-5
- [9] N. Tounsi, J. Vincenti, A. Otho, and M. A. Elbestawi, “From the basic mechanics of orthogonal metal cutting toward the identification of the constitutive equation,” Int. J. of Machine Tools and Manufacture, Vol.42, No.12, pp. 1373-1383, 2002. https://doi.org/10.1016/S0890-6955(02)00046-9
- [10] B. Li, X. Wang, Y. Hu, and C. Li, “Analytical prediction of cutting forces in orthogonal cutting using unequal division shear-zone model,” The Int. J. of Advanced Manufacturing Technology, Vol.54, No.5, pp. 431-443, 2011. https://doi.org/10.1007/s00170-010-2940-8
- [11] X. Song, W. He, and T. Ihara, “Predicting periodic evolution of BUE formation mechanisms during machining ductile material using damage mechanics,” Mechanical Engineering J., Vol.3, No.6, 15-00534, 2016. https://doi.org/10.1299/mej.15-00534
- [12] X. Song, H. Fujita, Y. Takahashi, W. He, and T. Ihara, “Thermomechanical modeling of the stress state in the chip formation zone considering the built-up layer and built-up edge formation,” 18th Int. Conf. on Precision Engineering (ICPE2020), B-1-13, 2020.
- [13] X. Song, Y. Takahashi, W. He, and T. Ihara, “Effects of the size of built-up layer on the wear of cemented carbide tools in cutting of SUS304 stainless steel,” J. of Advanced Mechanical Design, Systems, and Manufacturing, Vol.15, No.4, JAMDSM0050, 2021. https://doi.org/10.1299/jamdsm.2021jamdsm0050
- [14] T. Özel and E. Zeren, “A methodology to determine work material flow stress and tool-chip interfacial friction properties by using analysis of machining,” J. of Manufacturing Science and Engineering, Vol.128, No.1, pp. 119-129, 2006. https://doi.org/10.1115/1.2118767
- [15] G. R. Johnson and W. H. Cook, “A constitutive model and data for metals subjected to large strains, high strain rates, and high temperatures,” Proc. of the 7th Int. Symp. on Ballistics, pp. 541-547, 1983.
- [16] E. Usui and T. Shirakashi, “Numerical analysis of distribution of cutting temperature —Fundamental study on effects of temperature and strain-rate in metal machining (Part 3)—,” J. of the Japan Society of Precision Engineering, Vol.38, No.449, pp. 510-517, 1972 (in Japanese). https://doi.org/10.2493/jjspe1933.38.510
- [17] B. Shi, H. Attia, and N. Tounsi, “Identification of material constitutive laws for machining—Part I: An analytical model describing the stress, strain, strain rate, and temperature fields in the primary shear zone in orthogonal metal cutting,” J. of Manufacturing Science and Engineering, Vol.132, No.5, 051008, 2010. https://doi.org/10.1115/1.4002454
- [18] A. H. Adibi-Sedeh, V. Madhavan, and B. Bahr, “Extension of Oxley’s analysis of machining to use different material models,” J. of Manufacturing Science and Engineering, Vol.125, No.4, pp. 656-666, 2003. https://doi.org/10.1115/1.1617287
- [19] E. Usui, “Modern Cutting Theory,” Kyoritsu Shuppan Co., Ltd., 1990 (in Japanese).
- [20] X. Song, Y. Takahashi, and T. Ihara, “Prediction of built-up layer and built-up edge formation in dry cutting of SUS304 stainless steel,” Int. J. Automation Technol., Vol.13, No.1, pp. 13-21, 2019. https://doi.org/10.20965/ijat.2019.p0013
- [21] E. M. Trent and P. K. Wright, “Metal Cutting,” 4th Edition, Butterworth-Heinemann, 2000.
- [22] M. C. Shaw, “Metal Cutting Principles,” 2nd Edition, Oxford University Press, 2004.
- [23] R. Makino, K. Kishi, and K. Hoshi, “Built-up edge phenomenon on the cutting of low carbon steel,” J. of the Japan Society of Precision Engineering, Vol.39, No.458, pp. 299-305, 1973 (in Japanese). https://doi.org/10.2493/jjspe1933.39.299
- [24] N. S. Brar, V. S. Joshi, and B. W. Harris, “Constitutive model constants for Al7075-T651 and Al7075-T6,” AIP Conf. Proc., Vol.1195, No.1, pp. 945-948, 2009. https://doi.org/10.1063/1.3295300
- [25] J. Lu, Y. Song, L. Hua, K. Zheng, and D. Dai, “Thermal deformation behavior and processing maps of 7075 aluminum alloy sheet based on isothermal uniaxial tensile tests,” J. of Alloys and Compounds, Vol.767, pp. 856-869, 2018. https://doi.org/10.1016/j.jallcom.2018.07.173
- [26] T. Zhang, Z.-R. Guo, F.-P. Yuan, and H.-S. Zhang, “Investigation on the plastic work-heat conversion coefficient of 7075-T651 aluminum alloy during an impact process based on infrared temperature measurement technology,” Acta Mechanica Sinca, Vol.34, No.2, pp. 327-333, 2018. https://doi.org/10.1007/s10409-017-0673-8
- [27] Y. Bao and T. Wierzbicki, “On fracture locus in the equivalent strain and stress triaxiality space,” Int. J. of Mechanical Sciences, Vol.46, No.1, pp. 81-98, 2004. https://doi.org/10.1016/j.ijmecsci.2004.02.006
- [28] N. Rom, J. Bortman, and E. Priel, “Predicting ductile failure of aluminum components under general loading conditions: Computational implementation, model verification and experimental validation,” Int. J. of Solids and Structures, Vol.275, 112295, 2023. https://doi.org/10.1016/j.ijsolstr.2023.112295
- [29] J. Kümmel, J. Gibmeier, E. Müller, R. Schneider, V. Schulze, and A. Wanner, “Detailed analysis of microstructure of intentionally formed built-up edges for improving wear behaviour in dry metal cutting process of steel,” Wear, Vol.311, Nos.1-2, pp. 21-30, 2014. https://doi.org/10.1016/j.wear.2013.12.012
This article is published under a Creative Commons Attribution-NoDerivatives 4.0 Internationa License.