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Evaluating performance metrics in non-homogeneous cutting processes using a random-grid based digital image correlation (DIC) method

Gupta, D and Udupa, A and Viswanathan, K (2021) Evaluating performance metrics in non-homogeneous cutting processes using a random-grid based digital image correlation (DIC) method. In: Manufacturing Letters, 30 . pp. 44-48.

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Official URL: https://doi.org/10.1016/j.mfglet.2021.10.004

Abstract

The mechanics of chip formation is widely known to be a robust indicator of cutting performance. While chips have been studied and classified for several decades, a direct quantitative correlation between chip morphology and properties of the resulting machined surface is yet to be established. In this work, we develop and demonstrate a digital image correlation (DIC) technique that specifically addresses this issue. Our technique is a departure from standard DIC methods in that it uses an iterative technique on multiple independent random grids, allowing us to obtain accurate full-field deformation measurements during chip formation. The method works especially well at or near free surfaces (e.g., machined surface) and interfaces (e.g., tool-chip contact) and when deformation is temporally unsteady and spatially non-homogeneous. Given that these are central features of nearly all cutting processes, we show how our technique can quantify unsteady, non-uniform flow fields, residual surface and near-surface strains, as well as the amount of redundant deformation during chip formation. These results suggest the use of a simple heuristic test to evaluate critical process performance metrics, such as part surface quality, sub-surface damage and relative energy consumption during machining. © 2021 Society of Manufacturing Engineers (SME)

Item Type: Journal Article
Publication: Manufacturing Letters
Publisher: Elsevier Ltd
Additional Information: The copyright for this article belongs to Elsevier Ltd
Keywords: Cutting; Deformation; Energy utilization; Image analysis; Iterative methods; Machining; Morphology; Strain; Strain measurement, Chip formations; Cutting process; Digital image correlation methods; Digital image correlations; Non-homogeneous; Performance metrices; Process performance; Random grids; Residual strains; Unsteady plastic flow, Cutting tools
Department/Centre: Division of Mechanical Sciences > Mechanical Engineering
Date Deposited: 03 Dec 2021 08:48
Last Modified: 03 Dec 2021 08:48
URI: http://eprints.iisc.ac.in/id/eprint/70623

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