Abstract: Methods of inducing segmented flow in a material in which a ductile flow mode would otherwise occur during machining. A monolayer molecular film is formed on a surface of a body of a material in a state such that the material exhibits ductile flow when subjected to shear. The monolayer molecular film has molecules each having a head group adsorbed to the surface, a terminal group, and a hydrocarbon chain therebetween having a chain length of greater than 6. A surface portion of the body is removed by engaging the body with a tool in a contact region below the surface of the body and moving the tool relative to the body to remove the surface portion and the monolayer molecular film thereon. The monolayer molecular film induces segmented flow in the material during the removing of the surface portion.

Abstract: Processes for producing continuous bulk forms of iron-silicon alloys and bulk forms produced thereby. Such a bulk form is continuous in a longitudinal direction thereof and has a continuous cross-sectional form transverse to the longitudinal direction. The bulk form is formed of an Fe—Si alloy and has a crystallographic texture that comprises <111> and {110} fibers that are inclined relative to the longitudinal direction. The bulk form may be produced by a process that includes deforming a solid body formed of an Fe—Si alloy with a cutting tool in a single step to continuously produce a continuous bulk form from material obtained from the solid body.

Abstract: Methods of machining a body to produce a chip wherein the body is formed of a material and in a state such that the material exhibits sinuous flow during a machining operation. The methods include providing a layer located on a surface of the body, and machining the body by causing engagement between a cutting tool and the body in a contact region below an area of the surface having the coating layer thereon and moving the cutting tool relative to the body to produce the chip having the layer thereon. The layer reduces sinuous flow in the material of the body.

Abstract: Methods of inducing segmented flow in a material in which a ductile flow mode would otherwise occur during machining. A monolayer molecular film is formed on a surface of a body of a material in a state such that the material exhibits ductile flow when subjected to shear. The monolayer molecular film has molecules each having a head group adsorbed to the surface, a terminal group, and a hydrocarbon chain therebetween having a chain length of greater than 6. A surface portion of the body is removed by engaging the body with a tool in a contact region below the surface of the body and moving the tool relative to the body to remove the surface portion and the monolayer molecular film thereon. The monolayer molecular film induces segmented flow in the material during the removing of the surface portion.

Abstract: A method for controlling flow localization in machining process is disclosed. By application of a constraint of sufficient level in the deformation zone and modifying the surface boundary conditions, suppression of unsteady flow and flow instabilities is achieved. The method enhances machined component quality by ensuring a uniform deformation state on the machined surface. Machined components are produced by ensuing uniform deformation by adopting constrained-cutting process for suppressing the instabilities and unsteady flow through a pre-determined location of the constraint of the constrained machining process relative to the machining tool.

Abstract: Processes for producing sheet metal products by machining a solid metal body with a cutting tool in a single step to continuously produce a continuous bulk form from material obtained from the solid metal body, and without performing a hot rolling operation thereon, cold rolling the continuous bulk form to produce a sheet metal product. The machining step is a large-strain machining process capable of being directly performed on an as-cast ingot or other solid body to produce a continuous intermediate product that can be directly cold rolled without any intervening hot rolling operation, and optionally without homogenization or annealing.

Abstract: Methods of machining a body to produce a chip wherein the body is formed of a material and in a state such that the material exhibits sinuous flow during a machining operation. The methods include providing a layer located on a surface of the body, and machining the body by causing engagement between a cutting tool and the body in a contact region below an area of the surface having the coating layer thereon and moving the cutting tool relative to the body to produce the chip having the layer thereon. The layer reduces sinuous flow in the material of the body.

Abstract: Processes for producing continuous bulk forms of iron-silicon alloys and bulk forms produced thereby. Such a bulk form is continuous in a longitudinal direction thereof and has a continuous cross-sectional form transverse to the longitudinal direction. The bulk form is formed of an Fe—Si alloy and has a crystallographic texture that comprises <111> and {110} fibers that are inclined relative to the longitudinal direction. The bulk form may be produced by a process that includes deforming a solid body formed of an Fe—Si alloy with a cutting tool in a single step to continuously produce a continuous bulk form from material obtained from the solid body.

Abstract: Methods of machining a body to produce a chip are provided wherein the body is formed of a material and in a state such that the material exhibits sinuous flow during a machining operation. The methods include providing a layer located on a surface of the body, and machining the body by causing engagement between a cutting tool and the body in a contact region below an area of the surface having the coating layer thereon and moving the cutting tool relative to the body to produce the chip having the layer thereon. The layer reduces sinuous flow in the material of the body and the chip is formed primarily by laminar flow.

Abstract: Processes for producing continuous bulk forms of iron-silicon alloys and bulk forms produced thereby. Such a bulk form is continuous in a longitudinal direction thereof and has a continuous cross-sectional form transverse to the longitudinal direction. The bulk form is formed of an Fe—Si alloy and has a crystallographic texture that comprises <111> and {110} fibers that are inclined relative to the longitudinal direction. The bulk form may be produced by a process that includes deforming a solid body formed of an Fe—Si alloy with a cutting tool in a single step to continuously produce a continuous bulk form from material obtained from the solid body.

Abstract: Processes by which bulk forms can be produced in a single continuous operation, as opposed to multi-stage deformation processes that involve a series of separate and discrete deformation operations or stages. Such processes generally entail deforming a solid body using a large-strain extrusion machining technique and deformation conditions that obtain a predetermined crystallographic texture in the continuous bulk form that differs from the crystallographic texture of the solid body.

Abstract: Processes for producing continuous bulk forms of iron-silicon alloys and bulk forms produced thereby. Such a bulk form is continuous in a longitudinal direction thereof and has a continuous cross-sectional form transverse to the longitudinal direction. The bulk form is formed of an Fe—Si alloy and has a crystallographic texture that comprises <111> and {110} fibers that are inclined relative to the longitudinal direction. The bulk form may be produced by a process that includes deforming a solid body formed of an Fe—Si alloy with a cutting tool in a single step to continuously produce a continuous bulk form from material obtained from the solid body.

Abstract: Methods of machining a body to produce a chip are provided wherein the body is formed of a material and in a state such that the material exhibits sinuous flow during a machining operation. The methods include providing a layer located on a surface of the body, and machining the body by causing engagement between a cutting tool and the body in a contact region below an area of the surface having the coating layer thereon and moving the cutting tool relative to the body to produce the chip having the layer thereon. The layer reduces sinuous flow in the material of the body and the chip is formed primarily by laminar flow.

Abstract: Methods suitable for producing textured surfaces in surfaces of objects, by which the methods are able to achieve a desired three-dimensional surface topography and optionally a desired subsurface microstructure through the use of a controlled modulation machining technique. The methods include selecting a predetermined surface texture for a surface of a body, and then imposing a superimposed sinusoidal feed-modulation on a cutting tool so as to move the cutting tool in a feed direction relative to the body while machining the body with the cutting tool and generating a machined surface of the body. The surface texture of the machined surface is intentionally controlled by at least the modulation amplitude and the modulation frequency of the superimposed sinusoidal feed-modulation.

Abstract: A method for controlling flow localization in machining process is disclosed. By application of a constraint of sufficient level in the deformation zone and modifying the surface boundary conditions, suppression of unsteady flow and flow instabilities is achieved. The method enhances machined component quality by ensuring a uniform deformation state on the machined surface. Machined components are produced by ensuing uniform deformation by adopting constrained-cutting process for suppressing the instabilities and unsteady flow through a pre-determined location of the constraint of the constrained machining process relative to the machining tool.

Abstract: Methods suitable for producing textured surfaces in surfaces of objects, by which the methods are able to achieve a desired three-dimensional surface topography and optionally a desired subsurface microstructure through the use of a controlled modulation machining technique. The methods include selecting a predetermined surface texture for a surface of a body, and then imposing a superimposed sinusoidal feed-modulation on a cutting tool so as to move the cutting tool in a feed direction relative to the body while machining the body with the cutting tool and generating a machined surface of the body. The surface texture of the machined surface is intentionally controlled by at least the modulation amplitude and the modulation frequency of the superimposed sinusoidal feed-modulation.

Abstract: Processes by which bulk forms can be produced in a single continuous operation, as opposed to multi-stage deformation processes that involve a series of separate and discrete deformation operations or stages. Such processes generally entail deforming a solid body using a large-strain extrusion machining technique and deformation conditions that obtain a predetermined crystallographic texture in the continuous bulk form that differs from the crystallographic texture of the solid body.

Abstract: A products having at least a portion thereof with a nanocrystalline microstructure, and methods of producing such products. The method generally entails machining a body to produce a polycrystalline chip having a nanocrystalline microstructure. The chips produced by the machining operation may be in the form of particulates, ribbons, wires, filaments and/or platelets. The chips may be consolidated (with or without comminution) to form a product, such that the product is essentially a nanocrystalline monolithic material consisting essentially or entirely of nano-crystals, or of grains grown from nano-crystals. Alternatively, the chips may be dispersed in a matrix material, such that the product is a composite material in which the chips are dispersed as a reinforcement material. According to a particular aspect, a monolithic article can be formed entirely from a single chip by deforming the chip and/or removing material from the chip.

Abstract: A method of controllably producing chips with a desired shape and size. The method generally entails machining a body with a cutting tool while superimposing modulation on the cutting tool so as to move the cutting tool relative to the body being machined and cause instantaneous and periodic separation between the cutting tool and the body at a point of contact between the cutting tool and the body, wherein each separation between the cutting tool and the body yields a chip. In this manner, the shapes and sizes of the chips are determined at least in part by the modulation cycle, and particularly the length of time the cutting tool is engaged with the body being machined.

Abstract: A process by which nanostructured monolithic bodies can be produced in a single continuous operation, as opposed to multi-stage deformation processing. The process generally entails continuously producing a chip having a nanostructured microstructure by engaging a solid body with a cutting edge of a tool while the solid body and the cutting edge move relative to each other, and simultaneously extruding the chip in the immediate vicinity of the cutting edge, such as with a constraining member, as the chip is separated from the solid body by the cutting edge to continuously plastically deform the chip and produce a nanostructured monolithic body immediately downstream of the cutting edge. The shape and size of the chip can be simultaneously controlled by the extrusion process so that the nanostructured monolithic body has a predetermined geometry. The nanostructured monolithic body can be in the form of a product suitable for immediate use, or undergo further processing to yield a product.