In situ, high-speed imaging experiments have revealed the existence of sinuous flow, a recently discovered mode of chip formation in machining. The origin and consequences of sinuous flow are still being investigated, but it is now known that sinuous flow involves extensive redundant plastic deformation, poor surface finish and paradoxically high cutting forces. Here, we use full-scale simulations to show that microstructure related inhomogeneity is a major cause of sinuous flow. The simulations are conducted in a Lagrangian FE framework, and use a simple pseudograin model to represent the metal workpiece as a polycrystalline aggregate. The model successfully captures all essential features of sinuous flow in metals like OFHC copper and CP aluminum, and points to the importance of including material microstructure in cutting simulations.
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ASME 2018 13th International Manufacturing Science and Engineering Conference
June 18–22, 2018
College Station, Texas, USA
Conference Sponsors:
- Manufacturing Engineering Division
ISBN:
978-0-7918-5136-4
PROCEEDINGS PAPER
The Microstructural Origin of Sinuous Flow in Metal Cutting Available to Purchase
Vandana A. Salilkumar,
Vandana A. Salilkumar
Indian Institute of Science, Bangalore, India
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Narayan K. Sundaram
Narayan K. Sundaram
Indian Institute of Science, Bangalore, India
Search for other works by this author on:
Vandana A. Salilkumar
Indian Institute of Science, Bangalore, India
Narayan K. Sundaram
Indian Institute of Science, Bangalore, India
Paper No:
MSEC2018-6342, V002T04A020; 5 pages
Published Online:
September 24, 2018
Citation
A. Salilkumar, V, & Sundaram, NK. "The Microstructural Origin of Sinuous Flow in Metal Cutting." Proceedings of the ASME 2018 13th International Manufacturing Science and Engineering Conference. Volume 2: Materials; Joint MSEC-NAMRC-Manufacturing USA. College Station, Texas, USA. June 18–22, 2018. V002T04A020. ASME. https://doi.org/10.1115/MSEC2018-6342
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