The research and application of high speed metal cutting (HSMC) is aimed at achieving higher productivity and improved surface quality. This paper reviews the advancements in HSMC with a focus on the material removal mechanism and machined surface integrity without considering the effect of cutting dynamics on the machining process. In addition, the variation of cutting force and cutting temperature as well as the tool wear behavior during HSMC are summarized. Through comparing with conventional machining (or called as normal speed machining), the advantages of HSMC are elaborated from the aspects of high material removal rate, good finished surface quality (except surface residual stress), low cutting force, and low cutting temperature. Meanwhile, the shortcomings of HSMC are presented from the aspects of high tool wear rate and tensile residual stress on finished surface. The variation of material dynamic properties at high cutting speeds is the underlying mechanism responsible for the transition of chip morphology and material removal mechanism. Less surface defects and lower surface roughness can be obtained at a specific range of high cutting speeds, which depends on the workpiece material and cutting conditions. The thorough review on pros and cons of HSMC can help to effectively utilize its advantages and circumvent its shortcomings. Furthermore, the challenges for advancing and future research directions of HSMC are highlighted. Particularly, to reveal the relationships among inherent attributes of workpiece materials, processing parameters during HSMC, and evolution of machined surface properties will be a potential breakthrough direction. Although the influence of cutting speed on the material removal mechanism and surface integrity has been studied extensively, it still requires more detailed investigations in the future with continuous increase in cutting speed and emergence of new engineering materials in industries.

Advancements in material removal mechanism and surface integrity of high speed metal cutting: A review

The brittle-ductile transition (BDT) widely exists in the manufacturing with extremely small deformation scale, thermally assisted machining, and high-speed machining. This paper reviews the BDT in extreme manufacturing. The factors affecting the BDT in extreme manufacturing are analyzed, including the deformation scale and deformation temperature induced brittle-to-ductile transition, and the reverse transition induced by grain size and strain rate. A discussion is arranged to explore the mechanisms of BDT and how to improve the machinability based on the BDT. It is proposed that the mutual transition between brittleness and ductility results from the competition between the occurrence of plastic deformation and the propagation of cracks. The brittleness or ductility of machined material should benefit a specific manufacturing process, which can be regulated by the deformation scale, deformation temperature and machining speed.

https://iopscience.iop.org/article/10.1088/2631-7990/abdfd7/pdf

Towards understanding the brittle–ductile transition in the extreme manufacturing

Cutting forces and temperature measurements in cryogenic assisted turning of AA2024-T351 alloy: An experimentally validated simulation approach

Machining simulation of Ti6Al4V using coupled Eulerian-Lagrangian approach and a constitutive model considering the state of stress

For decades, attentions have been paid to metal cutting processes, especially for the critical components in aerospace, marine, medical industries, etc. Scholars investigated the influence of cutting parameters, tool geometry, lubricant, pursuing a deeper understanding of process signatures, better tool performance, and more superior surface integrity. Edge microgeometry is proved to be an essential factor that significantly influences the tool-workpiece-chip contact, plastic deformation, and heat generation, which in turn affects the cutting phenomena. This paper aims to provide an insight and scientific overview of the role of edge microgeometries in metal cutting, with special attention on material flow state, cutting mechanics, tool performance, as well as the surface integrity. The characterization of edge microgeometries includes edge types (honed, chamfered, mixed), size parameters (edge radius, form-factor K, chamfer angle, chamfer length), and edge preparation techniques (grinding, drag finishing, brushing, micro-blasting, etc.). The researches on the influence of edge microgeometries on material flow state and cutting mechanics are reviewed, mainly focusing on analytical modeling and finite element method to explain how the edge microgeometries affect cutting processes. Then, the researches on the influence of edge microgeometries on tool performance and surface integrity are well organized to present the various findings in these topics. From the current perspective, many scholars have noticed the importance of edge microgeometries in metal cutting and have done numerous researches on this topic. Summary and future suggestions are given based on their state-of-the-art contributions in the last section.

Cutting edge microgeometries in metal cutting: a review

Multiscale simulation of grain refinement induced by dynamic recrystallization of Ti6Al4V alloy during high speed machining

Prediction of microstructure gradient distribution in machined surface induced by high speed machining through a coupled FE and CA approach

\n Difficult-to-cut materials are widely used in aerospace and other industries. Titanium alloys are the most popular ones among them due to their high strength-to-weight ratio and high temperature resistance. However, in high-speed machining, the alloys are prone to produce serrated chips, which have a serious influence on surface integrity. In this study, a coupled Eulerian–Lagrangian method is used to simulate the orthogonal cutting of Ti6Al4V due to its advantages of avoiding element distortion and improving the data extraction efficiency. The internal relationship between serrated chip formation and periodic profile of machined surfaces is analyzed by the simulation results and experimental data which are obtained by optical microscope and white light interferometer. Furthermore, thermal–mechanical loads on machined surfaces are reconstructed based on the simulation results, and a coupled finite element and cellular automata approach is used to describe the dynamic recrystallization process within the area of the machined surface during the formation of a single serration. According to the results, the periodic fluctuation of cutting forces is attributed to the serrated chip formation phenomenon, which then leads to the periodic profile of machined surfaces. The period is about 60–70 µm, and its amplitude decreases with the increase of cutting speeds. Moreover, the loads on machined surfaces also show the same period due to serrated chip formation. As a result, the grain refinement layer thickness (about 2 ∼ 5 µm) in machined surfaces is related to the surface temperature and exhibits the same periodic characteristics along the cutting direction.

Serrated Chip Formation Induced Periodic Distribution of Morphological and Physical Characteristics in Machined Surface During High-Speed Machining of Ti6Al4V

Binbin Xu

Papers

Multiscale simulation of grain refinement induced by dynamic recrystallization of Ti6Al4V alloy during high speed machining

Machining simulation of Ti6Al4V using coupled Eulerian-Lagrangian approach and a constitutive model considering the state of stress

Prediction of microstructure gradient distribution in machined surface induced by high speed machining through a coupled FE and CA approach

Serrated Chip Formation Induced Periodic Distribution of Morphological and Physical Characteristics in Machined Surface During High-Speed Machining of Ti6Al4V

Whole process analysis of microstructure evolution during chip formation of high-speed machining OFHC copper