THE MICROSTRUCTURE INFLUENCE ON THE CHIP FORMATION PROCESS OF AL-CU ALLOY CAST CONVENTIONALLY AND IN SEMI SOLID STATE

For many metal alloys, the process of metal cutting is accompanied by extensive plastic deformation and fracture. To study this process, quick stop sectional samples of hypoeutectic Al-Cu alloy chip formation, either as conventionally cast alloy or as "semi solid metal" are used. The type of chip formation is classified according to crack formation mechanism and propagation. During cutting, in all specimens used, quasi-continuous chips with built-up edge (BUE) are obtained. The formation of BUE is undesirable since it is a highly deformed body with a semi stable top which periodically breaks away giving rise to poor workpiece surface quality.