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The flow dynamics, deformation fields and chip-particle formation in cutting and sliding of metals are analysed,in situ , using high-speed imaging and particle image velocimetry. The model system is a brass workpiece loaded against a wedge indenter at low speeds. At large negative rake angles, the flow is steady with a prow of material forming ahead of the indenter. There is no material removal and a uniformly strained layer develops on the workpiece surface—the pure sliding regime. When the rake angle is less negative, the flow becomes unsteady, triggered by formation of a crack on the prow free surface and material removal ensuing—the cutting regime. The strain on the prow surface at crack initiation is found to be constant. Chip morphologies, such as discrete particle, segmented chip and continuous chip with mesoscale roughness, are shown to arise from a universal mechanism involving propagation of the prow crack, but to different distances towards the indenter tip. The simple shear deformation in continuous chip formation shows small-angle oscillations also linked to the prow crack. Implications for material removal processes and ductile failure are discussed.

In situ analysis of flow dynamics and deformation fields in cutting and sliding of metals