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What Do Chip Morphologies Tell Us About the Cutting Process?

Viswanathan, K and Udupa, A and Sagapuram, D and Mann, JB (2019) What Do Chip Morphologies Tell Us About the Cutting Process? [Book Chapter]

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Official URL: https://doi.org/10.1007/978-981-32-9417-2_28


Chip morphologies have been documented, classified and characterized for decades within the metal cutting community. Based on these studies, it is generally appreciated that chip morphologies reflect the underlying cutting process. However, specific details of plastic flow processes that are responsible for chip shape, roughness and morphology have hitherto remained largely unclear. In this work, we show a unique correspondence between mesoscale (10–100 µm) plastic flow modes and resulting in chip morphologies. Using high-speed in situ observations and image analysis, we demonstrate three distinct plastic flow modes—all non-homogeneous and unsteady—that are unlike the usually assumed homogeneous shear plane/zone models for metal cutting. These flow modes have their own unique initiation and evolution criteria, as reflected in chip strains and material flow patterns. The latter are computed directly using image correlation techniques. The results show that all prior chip classifications can be collapsed into four primary chip types. Flow transitions between these types are also demonstrated using simple material-independent and non-metallurgical techniques.

Item Type: Book Chapter
Publication: Lecture Notes on Multidisciplinary Industrial Engineering
Publisher: Springer Nature
Additional Information: The copyright for this article belongs to the Springer Nature.
Keywords: Deformation processing; Metal cutting; Plasticity
Department/Centre: Division of Mechanical Sciences > Mechanical Engineering
Date Deposited: 13 Jul 2023 09:43
Last Modified: 13 Jul 2023 09:43
URI: https://eprints.iisc.ac.in/id/eprint/82431

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