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<p>This paper presents a high-resolution characterization of tool–chip interfacial stress distribution in cutting of a ductile metal using full-field photoelasticity. Our findings reveal the complex nature of stress distribution and friction along the contact, influenced by tool geometry. Notably, for negative rake-angle tools, the measurements reveal a distinct zone near the tool tip where the shear stress decreases as one travels toward the tool tip. Stress measurements are complemented with <i>in situ</i> velocimetry of chip flow at the interface to enable correlation between stresses and velocity distribution at the interface. Based on the data, the tool–chip interface is categorized into three distinct zones: (1) a retardation zone near the tool tip, characterized by a high normal stress but small shear stresses, followed by (2) a uniform sliding zone with a relatively constant shear stress and (3) an elastic zone near the contact edge that obeys Coulomb friction. The paper challenges the customary practice of dividing the tool–chip contact into sticking and sliding zones and instead argues for a contact description, in terms of plastic and elastic zones that is more consistent with the experimental observations. The study also highlights the importance of high-resolution <i>in situ</i> characterization techniques for resolving the complex nature of friction in cutting and other similar sliding plastic contacts.</p> Graphical abstract <p></p>

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On the Nature of Contact Friction and Stress Distribution in Cutting: In situ Photoelastic Study

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年7月2日

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  • Jobin T. Mathews,
  • Harshit Chawla,
  • Dinakar Sagapuram

摘要

This paper presents a high-resolution characterization of tool–chip interfacial stress distribution in cutting of a ductile metal using full-field photoelasticity. Our findings reveal the complex nature of stress distribution and friction along the contact, influenced by tool geometry. Notably, for negative rake-angle tools, the measurements reveal a distinct zone near the tool tip where the shear stress decreases as one travels toward the tool tip. Stress measurements are complemented with in situ velocimetry of chip flow at the interface to enable correlation between stresses and velocity distribution at the interface. Based on the data, the tool–chip interface is categorized into three distinct zones: (1) a retardation zone near the tool tip, characterized by a high normal stress but small shear stresses, followed by (2) a uniform sliding zone with a relatively constant shear stress and (3) an elastic zone near the contact edge that obeys Coulomb friction. The paper challenges the customary practice of dividing the tool–chip contact into sticking and sliding zones and instead argues for a contact description, in terms of plastic and elastic zones that is more consistent with the experimental observations. The study also highlights the importance of high-resolution in situ characterization techniques for resolving the complex nature of friction in cutting and other similar sliding plastic contacts.

Graphical abstract