Viscous Shear Banding in Cutting of Metals

Author(s):  
Dinakar Sagapuram ◽  
Koushik Viswanathan

Shear banding is a type of plastic flow instability with often adverse implications for cutting and deformation processing of metals. Here, we study the mechanics of plastic flow evolution within single shear bands in two different (Ti and Ni-based) alloy systems. The local shear band displacement profiles are quantitatively mapped at high resolution using a special micro-marker technique. The results show that shear bands, once nucleated, evolve by a universal viscous sliding mechanism that is independent of microstructural details. The evolution of local deformation around the band is accurately captured using a simple momentum diffusion model by assuming Bingham flow rheology for the band material. The predicted band viscosity is very small, comparable to those of liquid metals. A plausible explanation for this small viscosity and fluid-like behavior at the band, based on phonon drag, is presented.

Author(s):  
Dinakar Sagapuram ◽  
Koushik Viswanathan

Shear banding is a type of plastic flow instability with often adverse implications for cutting and deformation processing of metals. Here, we study the mechanics of plastic flow evolution within single shear bands in Ti- and Ni-based alloy systems. The local shear band displacement profiles are quantitatively mapped at high resolution using a special micromarker technique. The results show that shear bands, once nucleated, evolve by a universal viscous sliding mechanism that is independent of microstructural details. The evolution of local deformation around the band is accurately captured by a momentum diffusion equation based on a Bingham-type flow rule. The predicted band viscosity is very small, compared to those of liquid metals. A plausible explanation for this small viscosity and fluid-like behavior at the band, based on phonon drag, is presented.


2006 ◽  
Vol 21 (6) ◽  
pp. 1570-1575 ◽  
Author(s):  
W.H. Jiang ◽  
F.X. Liu ◽  
D.C. Qiao ◽  
H. Choo ◽  
P.K. Liaw

Using geometrically constrained specimens, the plastic flow behaviors of the as-cast and the relaxed Zr52.5Cu17.9Ni14.6Al10.0Ti5.0 bulk metallic glass in the dynamic compression were investigated. Both alloys exhibit a significant plasticity in the dynamic compression. The plastic deformation in both alloys is still inhomogeneous, which is characterized by the serrated plastic flow and the formation of shear bands. Free volumes affect the shear banding and the plastic flow. The reduced free volume results in the deviation of the shear banding direction from the maximum shear stress. The relaxed alloy exhibits the obvious stress overshoot, which is consistent with the theoretical prediction using a free volume model.


1991 ◽  
Vol 44 (11S) ◽  
pp. S20-S26
Author(s):  
A. E. Bayoumi ◽  
R. B. Joshi ◽  
H. M. Zbib

An experimental method using a digital image processing technique is developed for the purpose of characterizing material behavior at large elastoplastic deformations and the associated phenomenon of localization of plastic flow into shear bands. This allows for a detailed description of the evolution of the nonuniform deformation pattern in the post-localization regime. The experimental results are utilized to calibrate a recently developed gradient-dependent constitutive equation which takes into account the effect of heterogeneous plastic flow, anisotropy and large deformations. The measured values of the gradient coefficients are of small magnitude suggesting that higher order gradients are important only in the highly inhomogeneous region as expected. Moreover, it is found that anisotropic effects become significant in the post-localization regime where the anisotropy ratio changes considerably.


Author(s):  
Dinakar Sagapuram ◽  
Koushik Viswanathan ◽  
Anirban Mahato ◽  
Narayan K. Sundaram ◽  
Rachid M'Saoubi ◽  
...  

Shear banding is a plastic flow instability with highly undesirable consequences for metals processing. While band characteristics have been well studied, general methods to control shear bands are presently lacking. Here, we use high-speed imaging and micro-marker analysis of flow in cutting to reveal the common fundamental mechanism underlying shear banding in metals. The flow unfolds in two distinct phases: an initiation phase followed by a viscous sliding phase in which most of the straining occurs. We show that the second sliding phase is well described by a simple model of two identical fluids being sheared across their interface. The equivalent shear band viscosity computed by fitting the model to experimental displacement profiles is very close in value to typical liquid metal viscosities. The observation of similar displacement profiles across different metals shows that specific microstructure details do not affect the second phase. This also suggests that the principal role of the initiation phase is to generate a weak interface that is susceptible to localized deformation. Importantly, by constraining the sliding phase, we demonstrate a material-agnostic method—passive geometric flow control—that effects complete band suppression in systems which otherwise fail via shear banding.


1999 ◽  
Vol 42 (1) ◽  
pp. 61-71 ◽  
Author(s):  
A.V Dobromyslov ◽  
N.I Taluts ◽  
N.V Kazantseva ◽  
E.A Kozlov

2007 ◽  
Vol 22 (10) ◽  
pp. 2655-2658 ◽  
Author(s):  
W.H. Jiang ◽  
F.X. Liu ◽  
F. Jiang ◽  
K.Q. Qiu ◽  
H. Choo ◽  
...  

We investigated the effect of strain rate on the plastic-flow stress of a Zr-based bulk-metallic glass in quasistatic compression. The results indicate that the plastic-flow stress is dependent on the strain rate: an increase in the strain rate leads to a decrease in the plastic-flow stress, and vice versa. However, simply loading, unloading, and reloading at a constant strain rate do not change the plastic-flow stress. This strain-rate dependence of the plastic-flow stress may be related to shear-banding operations.


2018 ◽  
Vol 115 (28) ◽  
pp. 7212-7217 ◽  
Author(s):  
Shuo Guo ◽  
Devranjan Samanta ◽  
Yi Peng ◽  
Xinliang Xu ◽  
Xiang Cheng

Bacterial suspensions—a premier example of active fluids—show an unusual response to shear stresses. Instead of increasing the viscosity of the suspending fluid, the emergent collective motions of swimming bacteria can turn a suspension into a superfluid with zero apparent viscosity. Although the existence of active superfluids has been demonstrated in bulk rheological measurements, the microscopic origin and dynamics of such an exotic phase have not been experimentally probed. Here, using high-speed confocal rheometry, we study the dynamics of concentrated bacterial suspensions under simple planar shear. We find that bacterial superfluids under shear exhibit unusual symmetric shear bands, defying the conventional wisdom on shear banding of complex fluids, where the formation of steady shear bands necessarily breaks the symmetry of unsheared samples. We propose a simple hydrodynamic model based on the local stress balance and the ergodic sampling of nonequilibrium shear configurations, which quantitatively describes the observed symmetric shear-banding structure. The model also successfully predicts various interesting features of swarming vortices in stationary bacterial suspensions. Our study provides insights into the physical properties of collective swarming in active fluids and illustrates their profound influences on transport processes.


2021 ◽  
Author(s):  
Laetitia Le Pourhiet

<p>Tectonic modelling is a very wide area of application over a large range of time scale and length scale. What mainly characterize this modelling field is the coexistence of brittle fractures which relates to the field of fracture mechanics and plastic to viscous shear zones which belongs to the two main branch of continuum mechanics (solid and fluid respectively).</p><p>This type of problems arises sometimes in engineering but material do not change their behavior with loading rate or with time or with temperature, and rarely are engineers interested in modelling large displacement in post failure stage.  As a result, tectonicists cannot use commercial packages to simulate their problems and need to develop methodologies specific to their field.</p><p>Historically, the first tectonics models made use of simple analogue materials and corresponded more to modelism than actual analogue models. While the imaging of the models, and the characterization of the analogue materials have made a lot of progress in the last 15 years, up to recently, most analogue models still relied on sand and silicone putty to represent the brittle and viscous counter part of tectonic plates.</p><p>Since the late 80’s, but mostly during the years 2000, numerical modelling has exploded on the market, as contrarily to analogue modelling, it was easier to capture the thermal dependence of frictional-viscous transition, I use frictional here because most models in tectonics use continuum mechanics approach and in fine do not include brittle material s.s. but rather frictional shear bands. Some groups run these types of simulation routinely in 3D today but this performance has been made at the cost of a major simplification in the rheology: the disappearance of elasticity and compressibility which was present in late 90’s early 2000 simulations and is still very costly because the treatment of “brittle” rheology seriously amped code performances.</p><p>Until recently, in both analogue and numerical modelling, I have some kind of feeling that we have been running the same routine experiments over and over again with better performance, or better acquisition.  </p><p>We are now entering a new exciting era in tectonic modelling both from experimental and numerical side: a ) emergence of complex analogue material or rheological laws that efforts in upscaling from micro-mechanical process observed on the field to plate boundary scale, or from earthquake cycle to plate tectonics, b) emergence of new interesting set up’s in terms of boundary conditions in 3D, c) development of robust numerical technics for brittle behavior d) development of new applications to make our field more predictive that will enlarge the community of end-users of the modelling results</p><p>I will review these novelties with some of the work develop with colleagues and students but also with examples from the literature and try to quickly draw a picture of where we are at and where we go.</p>


Author(s):  
H. Lin ◽  
C. lu ◽  
H. Y. Wang ◽  
L. H. Dai

Ductile metallic glass foams (DMGFs) are a new type of structural material with a perfect combination of high strength and toughness. Owing to their disordered atomic-scale microstructures and randomly distributed macroscopic voids, the compressive deformation of DMGFs proceeds through multiple nanoscale shear bands accompanied by local fracture of cellular structures, which induces avalanche-like intermittences in stress–strain curves. In this paper, we present a statistical analysis, including distributions of avalanche size, energy dissipation, waiting times and aftershock sequence, on such a complex dynamic process, which is dominated by shear banding. After eliminating the influence of structural disorder, we demonstrate that, in contrast to the mean-field results of their brittle counterparts, scaling laws in DMGFs are characterized by different exponents. It is shown that the occurrence of non-trivial scaling behaviours is attributed to the localized plastic yielding, which effectively prevents the system from building up a long-range correlation. This accounts for the high structural stability and energy absorption performance of DMGFs. Furthermore, our results suggest that such shear banding dynamics introduce an additional characteristic time scale, which leads to a universal gamma distribution of waiting times.


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