Modeling of serrated chip formation in high speed orthogonal machining

Abstract

Modeling of serrated chip formation is important to provide guidance for further development of this process and predict the quality of machined parts. The simulation of serrated chip formation is hard to achieve due to the lack of a proper material model which represents real phenomenon within a narrow adiabatic shear band. In the present study, a material constitutive law containing strain hardening and thermal softening was proposed to predict adiabatic shear localization within serrated chips. The outcomes of FEM simulation show the capability to predict serrated chip formation. The effective strain distributions and the forces are computed within this study.