Abstract
In a recent paper on machining annealed copper at a low cutting speed, and at an uncut chip thickness one-tenth of the mean grain size of the copper, Udupa
et al
. (
Proc. R. Soc A
473
, 20160863,
doi:10.1098/rspa.2016.0863
) report chip thicknesses larger than 10 times the uncut thickness and then a new mode of chip formation. Plastic bulging occurs in the surface of the copper ahead of the tool, leading to chip formation by a series of folds. The strain in the chip is less than that expected in a chip formed by shear according to long-standing classical theory. The authors suggest that the foundations of that theory need to be re-examined. In response, continuum mechanics numerical simulations presented here show a continuous transition from the classical condition towards that observed by Udupa
et al
. as the ratio of chip thickness to uncut thickness increases above approximately 7. Bulging is obtained by introducing (approximately) material heterogeneity to the simulations at a grain size scale but whether such heterogeneity is essential for the bulging flows remains an open question.
Subject
General Physics and Astronomy,General Engineering,General Mathematics
Cited by
1 articles.
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1. Response to ‘Comment on “The cutting of metals via plastic buckling” by Udupa
et al.
’;Proceedings of the Royal Society A: Mathematical, Physical and Engineering Sciences;2019-01