Control of Shear Band Formation during Severe Plastic

AS RS

Deformation by a Roller Tip Cutting Tool

Abhishek Bihari1*, Anirban Mahato1
1Surface Engineering and Manufacturing Lab, Dept. of Mechanical Engg.,

Indian Institute of Technology Patna, Patna-801106, India

*abhishek_1921me05@iitp.ac.in

Abstract Results
 We are studying the metal cutting process with a new approach via considering rolling 4
5
motion at the tool tip rather than the conventional sliding motion.
 The work aims to control the dynamics of flow instability and shear localization in cutting.
Simulations are used to accomplish this, along with in-situ and ex-situ experiments.
 The rolling motion metal cutting approach lies in the boundary lubrication regime.
 Viscous flow through the gap between roller and the tool slot (considered as two concentric
cylinders) with varying eccentricities is studied with help of ANSYS that predicts flow
reversal at a critical eccentricity ratio of Ɛ= 0.4.
 Fusible alloys such as Wood’s metal and high strength material such as copper and titanium
is used as the material model.
 Metal cutting simulation is performed using ABAQUS to give a better understanding of the
chip formation mechanism. CFD Analysis predicting non-working conditions e.g. Flow reversal, Cavitation & Stresses on Roller Tool

Introduction
 The material removal in cutting process necessarily involves imposition of extreme plastic
deformation (strains of 1–10) in the chip and in vicinity of the machined surface, typically at
high strain rates(103–106 s-1) [1].
 The extreme deformation conditions in metal cutting produce a rich variety of chips e.g. • Bi, Sn, Pb and, Cd phases; Pb7Bi3, and Cd0.5Sn0.95 intermetallic compounds
Steady: continuous & Unsteady: mushroom-type, segmented & shear-localized, each arising • Avg Crystalline size : 40.01 nm
from a distinct mode and triggered by an instability phenomenon [2]. • Grain size : 18.83 μm
 Shear band flow is a two phase process, (i) initiation/nucleation at tool tip (ii) sliding phase • Miniature samples shows poor mechanical properties.
causing strain localization. One of the method to suppress the banding is inhibiting the
sliding phase by application of macroscopic constraints to the flow [3].

Mechanical and metallurgical properties of the casted Wood’s metal

(c) (d)
Laminar & Shear Localized flow Shear Bands Shear Band suppression

Methodology

FE simulation with Sharp & Roller Tool on Copper

Conclusions
 Metal cutting process using Roller Tip cutting tool lies in boundary lubrication regime.
 CFD analysis of the Taylor Couette flow reveals that the (i) critical eccentricity ratio for the
flow reversal is Ɛ=0.4. (ii) Mild steel, when used as the shank of the tool may fail under
laminar flow conditions and survive under turbulent flow conditions for Pressure of 1 MPa.
 Wood’s metal was successfully cast in the glass mold without any porosity present in the
sample which makes it suitable to be used for experimental purposes.
 Wood’s metal shows scaling effect. ASTM E8 samples in tensile test demonstrated thermal
softening in the material immediately after yielding, followed by a sharp decrease in flow
stress saturation beyond strains of approximately 30 - 35%.
 FE results conducted on copper showed that the Roller Tool produced chips with smaller
chip thickness along with no sign of segmentation.

References
1. Yadav, S., Feng, G., & Sagapuram, D. (2019). Dynamics of shear band instabilities in cutting
of metals. CIRP Annals, 68(1), 45-48.
2. Sagapuram, D., Udupa, A., Viswanathan, K., Mann, J. B., M’Saoubi, R., Sugihara, T., &
Chandrasekar, S. (2020). On the cutting of metals: A mechanics viewpoint. Journal of
Manufacturing Science and Engineering, 142(11).
3. Sagapuram, D., Viswanathan, K., Mahato, A., Sundaram, N. K., M'Saoubi, R., Trumble, K.
P., & Chandrasekar, S. (2016). Geometric flow control of shear bands by suppression of
viscous sliding. Proceedings of the Royal Society A: Mathematical, Physical and
Engineering Sciences, 472(2192), 20160167.

11 th Research Scholars' Day, Indian Institute of Technology Patna, March 23, 2022