Koushik Viswanathan

Geometric flow control of shear bands by suppression of viscous sliding.

Shear banding is a plastic flow instability with highly undesirable consequences for metals processing. While band characteristics have been well studied, general methods to control shear bands are presently lacking. Here, we use high-speed imaging and micro-marker analysis of flow in cutting to reveal the common fundamental mechanism underlying shear banding in metals. The flow unfolds in two distinct phases: an initiation phase followed by a viscous sliding phase in which most of the straining occurs. We show that the second sliding phase is well described by a simple model of two identical fluids being sheared across their interface. The equivalent shear band viscosity computed by fitting the model to experimental displacement profiles is very close in value to typical liquid metal viscosities. The observation of similar displacement profiles across different metals shows that specific microstructure details do not affect the second phase. This also suggests that the principal role of the initiation phase is to generate a weak interface that is susceptible to localized deformation. Importantly, by constraining the sliding phase, we demonstrate a material-agnostic method—passive geometric flow control—that effects complete band suppression in systems which otherwise fail via shear banding.

Sinuous flow in metals

Significance It is counterintuitive, yet well known, that cutting a soft metal, vis-à-vis a hardened one, involves significantly larger forces, with the formation of a thick chip. Using in situ imaging we show that this phenomenon results from a hitherto unidentified flow mode in metals, called sinuous flow due to its repeatedly folded nature, that resembles irreversible flows in geological rocks and some complex fluids. We also demonstrate how sinuous flow can be suppressed, by simply applying common marking ink remote from the cutting interface—the forces are reduced significantly and the thick chip is eliminated. Besides explaining some important decades-old phenomena in metal cutting, our work has broad implications for many natural and industrial cutting processes. Annealed metals are surprisingly difficult to cut, involving high forces and an unusually thick “chip.” This anomaly has long been explained, based on ex situ observations, using a model of smooth plastic flow with uniform shear to describe material removal by chip formation. Here we show that this phenomenon is actually the result of a fundamentally different collective deformation mode—sinuous flow. Using in situ imaging, we find that chip formation occurs via large-amplitude folding, triggered by surface undulations of a characteristic size. The resulting fold patterns resemble those observed in geophysics and complex fluids. Our observations establish sinuous flow as another mesoscopic deformation mode, alongside mechanisms such as kinking and shear banding. Additionally, by suppressing the triggering surface undulations, sinuous flow can be eliminated, resulting in a drastic reduction of cutting forces. We demonstrate this suppression quite simply by the application of common marking ink on the free surface of the workpiece material before the cutting. Alternatively, prehardening a thin surface layer of the workpiece material shows similar results. Besides obvious implications to industrial machining and surface generation processes, our results also help unify a number of disparate observations in the cutting of metals, including the so-called Rehbinder effect.

Nucleation and propagation of solitary Schallamach waves.

We isolate single Schallamach waves--detachment fronts that mediate inhomogeneous sliding between an elastomer and a hard surface--to study their creation and dynamics. Based on measurements of surface displacement using high-speed in situ imaging, we establish a Burgers vector for the waves. The crystal dislocation analogs of nucleation stress, defect pinning, and configurational force are demonstrated. It is shown that many experimentally observed features can be quantitatively described using a conventional model of a dislocation line in an elastic medium. We also highlight the evolution of nucleation features, such as surface wrinkles, with consequences for interface delamination.

Geometric treatment of conduction electron scattering by crystal lattice strains and dislocations

The problem of conduction electron scattering by inhomogeneous crystal lattice strains is addressed using a tight-binding formalism and the differential geometric treatment of deformations in solids. In this approach, the relative positions of neighboring atoms in a strained lattice are naturally taken into account, even in the presence of crystal dislocations, resulting in a fully covariant Schrodinger equation in the continuum limit. Unlike previous work, the developed formalism is applicable to cases involving purely elastic strains as well as discrete and continuous distributions of dislocations—in the latter two cases, it clearly demarcates the effects of the dislocation strain field and core. It also differentiates between elastic and plastic strain contributions, respectively. The electrical resistivity due to the strain field of edge dislocations is then evaluated and the resulting numerical estimate for Cu shows good agreement with reported experimental values. This indicates that the electrical resistivity of edge dislocations in metals is not entirely due to the core, contrary to current models. Application to the study of strain effects in constrained quantum systems is also discussed.

The cutting of metals via plastic buckling

The cutting of metals has long been described as occurring by laminar plastic flow. Here we show that for metals with large strain-hardening capacity, laminar flow mode is unstable and cutting instead occurs by plastic buckling of a thin surface layer. High speed in situ imaging confirms that the buckling results in a small bump on the surface which then evolves into a fold of large amplitude by rotation and stretching. The repeated occurrence of buckling and folding manifests itself at the mesoscopic scale as a new flow mode with significant vortex-like components—sinuous flow. The buckling model is validated by phenomenological observations of flow at the continuum level and microstructural characteristics of grain deformation and measurements of the folding. In addition to predicting the conditions for surface buckling, the model suggests various geometric flow control strategies that can be effectively implemented to promote laminar flow, and suppress sinuous flow in cutting, with implications for industrial manufacturing processes. The observations impinge on the foundations of metal cutting by pointing to the key role of stability of laminar flow in determining the mechanism of material removal, and the need to re-examine long-held notions of large strain deformation at surfaces.

Slow wave propagation in soft adhesive interfaces

Stick-slip in sliding of soft adhesive surfaces has long been associated with the propagation of Schallamach waves, a type of slow surface wave. Recently it was demonstrated using in situ experiments that two other kinds of slow waves-separation pulses and slip pulses-also mediate stick-slip (Viswanathan et al., Soft Matter, 2016, 12, 5265-5275). While separation pulses, like Schallamach waves, involve local interface detachment, slip pulses are moving stress fronts with no detachment. Here, we present a theoretical analysis of the propagation of these three waves in a linear elastodynamics framework. Different boundary conditions apply depending on whether or not local interface detachment occurs. It is shown that the interface dynamics accompanying slow waves is governed by a system of integral equations. Closed-form analytical expressions are obtained for the interfacial pressure, shear stress, displacements and velocities. Separation pulses and Schallamach waves emerge naturally as wave solutions of the integral equations, with oppositely oriented directions of propagation. Wave propagation is found to be stable in the stress regime where linearized elasticity is a physically valid approximation. Interestingly, the analysis reveals that slow traveling wave solutions are not possible in a Coulomb friction framework for slip pulses. The theory provides a unified picture of stick-slip dynamics and slow wave propagation in adhesive contacts, consistent with experimental observations.

Distinct stick-slip modes in adhesive polymer interfaces

Abstract Stick-slip, manifest as intermittent tangential motion between two solids, is a well-known friction instability that occurs in a number of natural and engineering systems. In the context of adhesive polymer interfaces, this phenomenon has often been solely associated with Schallamach waves, which are termed slow waves due to their slow propagation speeds. We study the dynamics of a model polymer interface using coupled force measurements and high speed in situ imaging, to explore the occurrence of stick-slip linked to other slow wave phenomena. Two new waves—slip pulse and separation pulse—both distinct from Schallamach waves, are described. The slip pulse is a sharp stress front that propagates in the same direction as the Schallamach wave, while the separation pulse involves local interface detachment and travels in the opposite direction. Transitions between these stick-slip modes are easily effected by changing the sliding velocity or normal load. The properties of these three waves, and their relation to stick-slip is elucidated. We also demonstrate the important role of adhesion in effecting wave propagation.

On the extraordinary strength of Prince Rupert's drops

Prince Ruperts drops (PRDs), also known as Batavian tears, have been in existence since the early 17th century. They are made of a silicate glass of a high thermal expansion coefficient and have the shape of a tadpole. Typically, the diameter of the head of a PRD is in the range of 5–15 mm and that of the tail is 0.5 to 3.0 mm. PRDs have exceptional strength properties: the head of a PRD can withstand impact with a small hammer, or compression between tungsten carbide platens to high loads of ∼15 000 N, but the tail can be broken with just finger pressure leading to catastrophic disintegration of the PRD. We show here that the high strength of a PRD comes from large surface compressive stresses in the range of 400–700 MPa, determined using techniques of integrated photoelasticity. The surface compressive stresses can suppress Hertzian cone cracking during impact with a small hammer or compression between platens. Finally, it is argued that when the compressive force on a PRD is very high, plasticity in t...

Kinematic flow patterns in slow deformation of a dense granular material

The kinematic flow pattern in slow deformation of a model dense granular medium is studied at high resolution using in situ imaging, coupled with particle tracking. The deformation configuration is indentation by a flat punch under macroscopic plane-strain conditions. Using a general analysis method, velocity gradients and deformation fields are obtained from the disordered grain arrangement, enabling flow characteristics to be quantified. The key observations are the formation of a stagnation zone, as in dilute granular flow past obstacles; occurrence of vortices in the flow immediately underneath the punch; and formation of distinct shear bands adjoining the stagnation zone. The transient and steady state stagnation zone geometry, as well as the strength of the vortices and strain rates in the shear bands, are obtained from the experimental data. All of these results are well-reproduced in exact-scale non-smooth contact dynamics simulations. Full 3D numerical particle positions from the simulations allow extraction of flow features that are extremely difficult to obtain from experiments. Three examples of these, namely material free surface evolution, deformation of a grain column below the punch and resolution of velocities inside the primary shear band, are highlighted. The variety of flow features observed in this model problem also illustrates the difficulty involved in formulating a complete micromechanical analytical description of the deformation.