Researchers at Purdue University discovered a simple way to control a type of metal deformation known as sinuous flow. Supressing the deformation could reduce the energy required to process metals and lead to more efficient machining.
The Purdue team used high-speed microphotography and analysis to study the effects of cutting ductile metals. Contrary to long-held assumptions that metals are sheared uniformly, the metal deformed into finely spaced folds when cut.
Findings showed the cutting force can be reduced 50 percent simply by painting metal with a standard marking ink.
By reducing force, the metal can be cut easily with less pressure on the tool. Applying less force also generates less heat and vibration, reducing tool wear and damage to the part being machined.
Understanding sinuous flow and its suppression and control could also lead to the design of new materials for energy absorption.
