Adiabatic shear band formation as a result of cryogenic CNC machining of elastomers

The traditional method for producing polymer-based products is the use of moulding technologies such as injection moulding. CNC machining methods are predominantly used for metal part manufacture. The use of CNC machining methods for direct machining of polymers has been discussed in previous studies, particularly for hard polymers such as polypropylene. The CNC machining of soft elastomers, such as ethylene vinyl acetate (EVA), even at significantly reduced temperatures presents a number of challenges, with one being the formation of a machining phenomenon termed adiabatic shear bands, which can lead to increased part surface roughness and reduced part quality. The adiabatic shear band is an area on a chip where the ductile properties of the material being machined have been exceeded and the heat generated does not have sufficient time to be removed. This can lead to permanent material damage resulting in reduced fatigue resistance. The adiabatic shear formation has the potential to be even more evident with the machining of elastomers, leading to rapid material degradation, poor surface finish characteristics, and reduced material attenuation. In this paper the state of the art in cryogenic manufacturing is described and the concept of cryogenic CNC machining of elastomers is discussed. The experimental work consists of machining EVA and Neoprene utilizing the described cryogenic CNC machining facility. Sample chips are taken from the experimental testing and analysed using a scanning electron microscope to illustrate the adiabatic shear band formation in some cases. It is observed that in order to reduce this effect, correct machining parameters corresponding to the elasticity values need to be used and the glass transition temperature needs to be maintained.