Rehbinder effect in ultraprecision machining of ductile materials

Rehbinder effect on ductile materials is observed when surfactant is applied on the material surface, which reduces the strength of material due to reduction in surface energy. Application of Rehbinder effect in conventional machining of ductile materials was studied previously which resulted in sig...

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Bibliographic Details
Published in:International journal of machine tools & manufacture 2018-10, Vol.133, p.47-60
Main Authors: Chaudhari, Akshay, Soh, Zhi Yuan, Wang, Hao, Kumar, A. Senthil
Format: Article
Language:English
Subjects:
Aluminum base alloys
Chip morphology
Computer simulation
Copper
Cutting force
Cutting speed
Dislocation density
Ductility
Finite element analysis
Finite element method
High speed machining
Joint strength
Machining
Morphology
Precision
Reduction
Rehbinder effect
Surface energy
Surface roughness
Surfactants
Ultraprecision machining
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Summary:Rehbinder effect on ductile materials is observed when surfactant is applied on the material surface, which reduces the strength of material due to reduction in surface energy. Application of Rehbinder effect in conventional machining of ductile materials was studied previously which resulted in significant reduction in chip thickness and cutting forces. In this paper, the Rehbinder effect on ultraprecision microcutting of ductile materials is presented. Microcutting experiments were conducted on annealed copper, hardened copper, aluminium alloys AA-6061-T6 and RSA-6061 of different grain sizes at varying uncut chip thickness and cutting speed. Permanent metal marker ink was used as a surfactant to induce Rehbinder effect. As a result, cutting and thrust forces were reduced by 50% for pure copper whereas a 30% reduction was observed on aluminium alloys along with a reduction in chip thickness for the sections where ink was applied. It is also evident that the Rehbinder effect contributes towards an improvement in surface roughness. The underlying mechanism responsible for the reduction in cutting forces and chip thickness is explained in relation to a dislocation density model and explored further by a finite element method simulation. Positive results of Rehbinder effect on microcutting demand further studies to characterise the effect on other surfactant-material pairs for the applications in ultraprecision machining. [Display omitted] •Surface-active media induce the Rehbinder effect in ultraprecision microcutting.•Chip morphology, cutting force, and surface roughness are influenced by Rehbinder effect.•Theoretical model explains the effect of ink-affected layer in microcutting.•Reduction in fracture toughness is induced by the Rehbinder effect.
ISSN:0890-6955
1879-2170
DOI:10.1016/j.ijmachtools.2018.05.009