The Effect of Microstructure on Chip Formation and Surface Defects in Microscale, Mesoscale, and Macroscale Cutting of Steel

Chip and surface samples from microscale, mesoscale, and macroscale cutting of 1045 steel revealed that workpiece microstructure plays an important role in chip formation and the formation of surface defects such as dimples. Heterogeneous finite element (FE) models at different cutting scales were developed to investigate the effect of microstructure on chip and surface dimple formation. Plastic strains were found to increase as the scale of …