Orthogonal cutting experiments using a quick-stop device are performed on Al2024-T3 and OFHC copper to study the chip–workpiece interface in a scanning electron microscope. Evidence of ductile tearing ahead of the tool at cutting speeds of has been found. A numerical finite element model is then developed to study the energy consumed in material separation in micro-cutting. The ductile fracture of Al2024-T3 in a complex stress state ahead of the tool is captured using a damage model. Chip formation is simulated via the use of a sacrificial layer and sequential elemental deletion in this layer. Element deletion is enforced when the accumulated damage exceeds a predetermined value. A Johnson–Cook damage model that is load history dependent and with strain-to-fracture dependent on stress, strain rate, and temperature is used to model the damage. The finite element model is validated using the cutting forces obtained from orthogonal micro-cutting experiments. Simulations are performed over a range of uncut chip thickness values. It is found that at lower uncut chip thickness values, the percentage of energy expended in material separation is higher than at higher uncut chip thicknesses. This work highlights the importance of the energy associated with material separation in the nonlinear scaling effect of specific cutting energy in micro-cutting.
Skip Nav Destination
e-mail: shreyes.melkote@me.gatech.edu
Article navigation
April 2007
Technical Papers
Evidence of Ductile Tearing Ahead of the Cutting Tool and Modeling the Energy Consumed in Material Separation in Micro-Cutting
Sathyan Subbiah,
Sathyan Subbiah
George W. Woodruff School of Mechanical Engineering,
Georgia Institute of Technology
, Atlanta, GA 30332
Search for other works by this author on:
Shreyes N. Melkote
Shreyes N. Melkote
George W. Woodruff School of Mechanical Engineering,
e-mail: shreyes.melkote@me.gatech.edu
Georgia Institute of Technology
, Atlanta, GA 30332
Search for other works by this author on:
Sathyan Subbiah
George W. Woodruff School of Mechanical Engineering,
Georgia Institute of Technology
, Atlanta, GA 30332
Shreyes N. Melkote
George W. Woodruff School of Mechanical Engineering,
Georgia Institute of Technology
, Atlanta, GA 30332e-mail: shreyes.melkote@me.gatech.edu
J. Eng. Mater. Technol. Apr 2007, 129(2): 321-331 (11 pages)
Published Online: September 11, 2006
Article history
Received:
February 18, 2006
Revised:
September 11, 2006
Citation
Subbiah, S., and Melkote, S. N. (September 11, 2006). "Evidence of Ductile Tearing Ahead of the Cutting Tool and Modeling the Energy Consumed in Material Separation in Micro-Cutting." ASME. J. Eng. Mater. Technol. April 2007; 129(2): 321–331. https://doi.org/10.1115/1.2712471
Download citation file:
Get Email Alerts
Evaluation of Machine Learning Models for Predicting the Hot Deformation Flow Stress of Sintered Al–Zn–Mg Alloy
J. Eng. Mater. Technol (April 2025)
Blast Mitigation Using Monolithic Closed-Cell Aluminum Foam
J. Eng. Mater. Technol (April 2025)
Irradiation Damage Evolution Dependence on Misorientation Angle for Σ 5 Grain Boundary of Nb: An Atomistic Simulation-Based Study
J. Eng. Mater. Technol (July 2025)
Related Articles
Microstructure-Level Model for the Prediction of Tool Failure in WC-Co Cutting Tool Materials
J. Manuf. Sci. Eng (August,2006)
Finite Element Modeling of Edge Trimming Fiber Reinforced Plastics
J. Manuf. Sci. Eng (February,2002)
Dynamic Material Behavior Modeling Using Internal State Variable Plasticity and Its Application in Hard Machining Simulations
J. Manuf. Sci. Eng (August,2006)
Experimental Tool Temperature Distributions in Oblique and Orthogonal Cutting Using Chip Breaker Geometry Inserts
J. Manuf. Sci. Eng (May,2006)
Related Proceedings Papers
Related Chapters
Cutting Performance and Wear Mechanism of Cutting Tool in Milling of High Strength Steel 34CrNiMo6
Proceedings of the 2010 International Conference on Mechanical, Industrial, and Manufacturing Technologies (MIMT 2010)
Applications of Elastic-Plastic Fracture Mechanics in Section XI, ASME Code Evaluations
Online Companion Guide to the ASME Boiler & Pressure Vessel Codes
Modeling of Cutting Force in Vibration-Assisted Machining
Vibration Assisted Machining: Theory, Modelling and Applications