Recently, Prof. Zhang’s Research Group from the School of Mechanical Engineering, published a research paper with the title of “Simulated and Experimental Analysis on Serrated Chip Formation for Hard Milling Process” in the internationally renowned journal of mechanical engineering《Journal of Manufacturing Processes》. This paper was selected as a key scientific article by international well-known organization in engineering field Advances in Engineering (AIE) and reported the findings on Dec.7, 2019. Binxun Li is the first author of this paper, Prof. Song Zhang is the corresponding author.

AIE is intended to globally disseminate research excellence across academia and in the wider community. AIE reaches a global audience of 850,000 professors and scientists per month who seek the key research news and accomplishments in engineering. AIE has a strict standard on key scientific article selection, and no more than 0.1% published articles around the world can receive this honor.

Hard milling is a specialized machining process that allows machine shops to mill parts that have a hardness higher than 50HRC. However, the process suffers from several shortfalls, namely: the onset of serrated chip ties up with cutting forces, tool-chip interface temperature and surface quality as well as dynamic behavior of cutting system. Therefore, it is imperative to explore the serrated chip formation with respect to physical aspects encountered in milling processes. Prof. Zhang’s research group established the FE milling model for hardened steel in Abaqus/Explicit, and verified this model by comparing cutting force and chip morphology with experimental results. Further, FE simulation results are used to clarify the mechanism of serrated chip formation as well as the generated micro-cracks at the very beginning in down milling process. The high value of shear stress component S₁₂ propagates from free surface to tool tip is assumed to be responsible for the micro-cracks generation. The dominant mechanism of serrated chip formation in machining of hardened steel is attributed to adiabatic shear instability, while the micro-cracks generation may promotes the serrated chip full development.

Professor Song Zhang's research group mainly focuses on high-efficiency machining mechanism and machined surface integrity of difficult-to-machined materials. In recent years, they have published nearly 40 papers regarding in《International Journal of Mechanical Sciences》,《Materials Science & Engineering A》,《Journal of Manufacturing Processes》, and other international mainstream journals.

The AIE report link:https://advanceseng.com/simulated-experimental-analysis-serrated-chip-formation-hard-milling-process/

Written by: Li Jianyong

Edited by：Che Huiqing