Method of strain-rate difference calculation in high-speed metal cutting

• A measurement and calculation method of strain rate in the cutting process is proposed.
• Strain rate of aluminum alloy 7050 in cutting process is obtained.
• The strain rate values during high-speed cutting is as high as Grade 105 s−1.
• The deformation rate in the rake face direction is higher than that in the shear plane direction.

High-speed machining has been widely studied around the world for its high efficiency and high quality. However, conducting a quantitative study on many physical parameters is difficult when cutting speed is high. A simple and effective measurement and calculation method is necessary in engineering application. From the flow point of view, a difference calculation method through mesh length measurement is proposed, which can be easily used to determine the strain rate distribution of high-speed cutting. The distribution of strain rates for aluminum alloy 7050 cutting has been obtained; the results show that the strain rates are as high as 105 s−1 during high-speed cutting, and the strain rates near the tool tip are higher than those in other areas in the second deformation zone. In the direction of shear plane, the strain rates are gradually reduced from the center of the first deformation zone to the exterior. The deformation rate in the rake face direction is higher than that in the shear plane direction.