Analytical and experimental study of shear localization in chip formation in orthogonal machining

A simplified theory of instability of plastic flow is applied to analyze the formation of shear localized chips in orthogonal machining. A flow localization parameter is expressed in terms of associated cutting conditions and properties of the workpiece material. The analysis, which indicates the important parameters in the cutting process, is used to investigate the effect of cutting conditions on the onset of shear localization and the formation of adiabatic shear banding in metal cutting. Comparisons are made between the analysis and experiments in which the flow localization parameter is obtained for several workpiece materials. The results of this investigation seem to support the analysis and its potential benefits in analyzing and/or remedying problems associated with chip formation and temperature generated in metal cutting. Presently at Advanced Technology Center, Valenite, Inc., Madison Heights,MI 48071, USA