Characterization of serrated chip formation based on in-situ imaging analysis in orthogonal cutting

Abstract The in-situ imaging of the cutting process exhibits outstanding advantages in reconstructing the precise and visual thermoplastic deformation fields. The physical and geometric characteristics of deformation fields provide a deeper understanding of the cutting processes. In this paper, a mechanism-image hybrid analysis method is proposed to acquire the characteristics of the serrated chip deformation in the orthogonal cutting of TA15 titanium alloy based on in-situ imaging. The established hybrid analysis method combines the shear-plane theory with the streamline method and image segmentation method, which realizes the identification of pixel coordinates of the main shear plane (MSP) and the primary shear zone (PSZ) and then the extraction of the physical and geometric variables from the digital image correlation (DIC) full-field measurements. Consequently, the variations of equivalent strain rate, strain, temperature, and the geometric characterizations of MSP and PSZ during an individual serration formation of TA15 titanium alloy were quantitatively investigated. It was found that the physical and geometric variables reached stability in the final stage of serration evolution and were averaged as the DIC-based equivalent characterizations to analyze the impact of cutting depth and tool rake angle. Meanwhile, the DIC-based equivalent characterizations were compared with the results obtained by the classical analytical models to illustrate the advantages of the DIC-based analysis. The findings also support that the established hybrid analysis method holds the potential to characterize the serrated chip formation of other materials and improve the models of PSZ.