Validating Continuum Model for Onset of Adiabatic Shear Banding during High Speed Cutting by Finite Element Method

High-speed cutting (HSC) is frequently adopted to manufacture parts in many industries, including aerospace and automotive. To manufacture high-quality parts, adiabatic shear banding (ASB), often observed on serrated chips of various metallic materials during the HSC process, should be suppressed and studied. ASB is formed due to work hardening of metallic materials and work softening induced by adiabatic heating. The onset of ASB during the orthogonal cutting of Ti6Al4V is modeled based on the continuum mechanics, taking both work hardening and work softening into considerations. The model is validated by finite element method (FEM) and experiments. Moreover, the ASB onset process is simulated in FEM to reveal the ASB formation mechanism. The effect of the mechanical properties of Ti6Al4V on the onset of ASB is investigated based on the Johnson-Cook model. The investigation reveals the main factors that affect the onset of ASB during the HSC process. Future work includes characterizing the mechanical behavior of Ti6Al4V after the onset of ASB during a cutting process by coupling the continuum mechanics and micromechanics.