The ‘skin effect’ of subsurface damage distribution in materials subjected to high-speed machining

  • The machining of difficult-to-machine materials, such as titanium alloys, hard and brittle materials and silicon carbide reinforced aluminum composite, has been suffering from the machining-induced damage (MID). Currently, various theories and techniques are available for machining of these materials but with their respective limitations. High-speed machining (HSM) is featured with high efficiency and high quality of a machined workpiece with no limitations to the workpiece materials. However, the fundamental mechanisms of HSM remain unknown, which obstructs its applications. This paper proposed the “skin effect” of MID in HSM. Based on the published work on MID, the paper identifies strain rate as the dominant factor for the “skin effect” although many other factors may also come to play. The paper elucidates that material deformation at high strain rates (> 103 s-1) leads to material embrittlement which in turn contributes to the “skin effect” of MID. The paper then discusses the “skin effect” in terms of dislocation kinetics and crack initiation and propagation. It provides guidance to predicting the material deformation and damage at a high strain-rate for applications ranging from the armor protection, quarrying, petroleum drilling, and high-speed machining of engineering materials.
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Zhang B, Yin J F. 2019. The 'skin effect' of subsurface damage distribution in materials subjected to high-speed machining. Int. J. Extrem. Manuf. 1, 012007.. DOI: 10.1088/2631-7990/ab103b
Zhang B, Yin J F. 2019. The 'skin effect' of subsurface damage distribution in materials subjected to high-speed machining. Int. J. Extrem. Manuf. 1, 012007.. DOI: 10.1088/2631-7990/ab103b

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