In situ strain measurement in metal cutting with geometrically defined cutting edge

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The machining process with geometrically defined cutting edge is characterized by a highly complex chip formation process. A number of models have been developed which describe the material flow during chip formation. These models can be used for the calculation of mechanical and thermal state variables in the chip formation zone, such as strain, stress and temperature. However, the chip formation models rely on several simplifying assumptions due to the circumstance that the cutting process is difficult to monitor. The subject of the first project period was the in situ measurement of the state of stress within the chip formation zone during the cutting process by means of high-energy synchrotron X-radiation. The influence of different cutting parameters on the stress state was to be determined. The findings contribute to the verification and extension of existing chip formation models. Further influencing variables on the stress state shall be considered in the second project period. These variables are the formation of built up edge, a multiphase material as well as microstructural changes in the material. Material parameters for the microstructural changes shall be determined by means of ECAP experiments (Equal Channel Angular Pressing) and shall be implemented in a cutting simulation model. The microstructural material properties will subsequently be varied in the cutting simulations. Their influence on the stress state can thereby be investigated.