| Analytical modeling of serrated chip formation for high-speed machining of aluminum alloys has received growing attention in the international machining research community in recent years due to the wide applications of high speed machining in various industries. A new analytical model of serrated chip formation was developed in this study. Taking into account the effects of strains, strain-rates, and temperatures, the new model predicts characteristic variation of cutting forces, temperatures, and chip morphology in high-speed machining of aluminum alloys.; The critical cutting conditions under which the chip begins to turn from continuous form into serrated form are determined. The effects of cutting conditions, tool geometry, and material property in high-speed machining are investigated. The model developed is validated by using the published experimental data. A good agreement has been reached between the predicted and experimental results.; The scope of the study is limited to orthogonal metal cutting with straight chip formation. 7075-T6 aluminum was selected as the work material investigated in the present study due to its increasing applications in the manufacturing industry in recent years. |
