Mechanism of Serrated Chip Formation in Cutting Process Using Digital Image Correlation Technique

Serrated chip, one of the major chip types in cutting process influences the quality of machined surface. However, the dynamic evolution of the serrated chip can hardly been quantitatively investigated, especially the fields of strain and stress in chip formation zone can hardly be detected. In this paper, the formation of serrated chip in machining Nickel aluminum bronze was captured by high-speed camera. The evolution history of displacement field during cutting process was obtained by the digital image correlation technique. Then the obtained displacement fields were treated as prescribed boundary conditions in finite element computation for strain and stress fields. Adopting the software Abaqus as a finite element computation platform, the strain and stress fields was observed, which can explain the formation of serrated chips from an experimental viewpoint. The work provided a new way to understand the mechanism of serrated chip formation in cutting process.