Title: Volume constancy and material continuity in metal cutting

Authors: Yury I. Zamashchikov

Addresses: Residual Stress and Distortion Laboratory, Department of Machine-building Equipment and Automation, Institute of Aeronautics, Mechanical Engineering and Transportation, Irkutsk State Technical University, 83 Lermontov Street, Irkutsk 664074, Russia

Abstract: The volume constancy and material continuity in metal cutting are analysed. It is shown that the main equations of the chip formation (Timé's and Ernst-Merchant's expressions) introduce the volume constancy, but do not define the material continuity. The condition of material continuity is understood as the coincidence of the chip compression ratio defined by the main equations with the corresponding strain calculated through the micro strains in the chip and their orientations relative to the chip axes. Therefore, among a great number of volume constancy solutions, the one is chosen satisfying the material continuity condition. The approach proposed is validated by the corrected interpretation of the main equations of the chip formation, by the shear angle prediction and by the in-plane shear residual stress prediction.

Keywords: metal cutting; volume constancy; material continuity; chip compression ratio; strain; shear angle prediction; shear residual stress; chip formation.

DOI: 10.1504/IJMMM.2015.071994

International Journal of Machining and Machinability of Materials, 2015 Vol.17 No.3/4, pp.233 - 258

Received: 31 Dec 2014
Accepted: 25 Feb 2015
Published online: 27 Sep 2015 *

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