Abstract
The rapidly increasing demand for miniature components machining processes has drawn more attention to micro-machining research. Flow stress has always been a significant base for analyzing plastic deformation in machining processes. However, few studies have been conducted to predict accurately the material flow stress in the micro-cutting processes. In order to describe size effect in micro-cutting, this paper discusses the development of a circular primary deformation zone model, calculates the strain gradient in the primary zone, and presents a new flow stress model based on the theory of strain gradient plasticity. First, a series of orthogonal cutting experiments are performed and flow stress is calculated from the experiment data. Results from the proposed model have been successfully validated with experimentally determined results. It shows that the flow stress in micro-cutting is influenced greatly by the feed rate and the cutting edge radius.
Article PDF
Similar content being viewed by others
References
Merchant ME (1945) Mechanics of the metal cutting process. Orthogonal cutting and type 2 chip. J Appl Phys 16(5):267–276. doi:10.1063/1.1707586
Partchapol S, Frank K, Taylan A (2004) Determination of flow stress for metal cutting simulation—a progress report. J Mater Process Technol 146:61–71. doi:10.1016/S0924-0136(03)00845-8
Subbiah S (2006) Some investigations of scaling effects in micro-cutting. Georgia Institute of Technology
Woon KS, Rahman M, Fang FZ, Neo KS, Liu K (2008) Investigations of tool edge radius effect in micromachining: a FEM simulation approach. J Mater Process Technol 195(1–3):204–211. doi:10.1016/j.jmatprotec.2007.04.137
Simoneau A, Ng E, Elbestawi MA (2007) Grain size and orientation effects when microcutting AISI 1045 steel. Ann CIRP 56:57–61. doi:10.1016/j.cirp.2007.05.016
Laheurte R, Cahuc O, Darnis P, Gerard A (2006) Behaviour law for cutting process. Int J Adv Manuf Technol 29:17–23. doi:10.1007/s00170-004-2498-4
Joshi SS (2004) An explanation for the size-effect in machining using strain gradient plasticity. J Manuf Sci E-T ASME 126:679–685. doi:10.1115/1.1688375
Liu K (2005) Processes modeling of micro-cutting including strain gradient effects. Georgia Institute of Technology
Nix WD, Gao H (1998) Indentation size effects in crystalline materials: a law for strain gradient plasticity. J Mech Phys Solids 46(3):411–425. doi:10.1016/S0022-5096(97)00086-0
Arsenlis A, Parks DM (1999) Crystallographic aspects of geometrically-necessary and statically-stored dislocation density. Acta Mater 47:1597–1611. doi:10.1016/S1359-6454(99)00020-8
Kopalinsky EM, Oxley PLB (1984) Size effects in metal removal processes. Inst Phys Conf Ser n70:389–396
Oxley PLB (1961) Mechanics of metal cutting. Int J Mach Tool D R 1(1–2):89–97. doi:10.1016/0020-7357(61)90046-4
Fang N (2003) Slip-line modeling of machining with a rounded-edge tool—Part II: analysis of the size effect and the shear strain-rate. J Mech Phys Solids 51(4):743–762. doi:10.1016/S0022-5096(02)00061-3
Liang SY (2006) Mechanical machining and metrology at micro/nano scale. Proc. SPIE 6280:1–8
Masuzawa T, Tönshoff HK (1997) Three-dimensional micromachining by machine tools. Ann CIRP 46(2):621–628
Qu S, Huang Y, Pharr GM, Hwang KC (2006) The indentation size effect in the spherical indentation of iridium: a study via the conventional theory of mechanism-based strain gradient plasticity. Int J Plast 22(7):1265–1286
Abu AR, Voyiadjis GZ (2004) Analytical and experimental determination of the material intrinsic length scale of strain gradient plasticity theory from micro- and nano-indentation experiments. Int J Plast 20(6):1139–1182
Johnson KL (1970) Correlation of indentation experiments. J Mech Phys Solids 18(2):115–126
Eleiche A, Campbell J (1976) Strain-rate effects during reverse torsional shear. Exp Mech 16(8):281–290
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
Open Access This is an open access article distributed under the terms of the Creative Commons Attribution Noncommercial License (https://creativecommons.org/licenses/by-nc/2.0), which permits any noncommercial use, distribution, and reproduction in any medium, provided the original author(s) and source are credited.
About this article
Cite this article
Wu, J., Liu, Z. Modeling of flow stress in orthogonal micro-cutting process based on strain gradient plasticity theory. Int J Adv Manuf Technol 46, 143–149 (2010). https://doi.org/10.1007/s00170-009-2049-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-009-2049-0