Tracing the birth of a dead zone : Lessons from in situ analysis of tool–workpiece interactions
(2026) In Journal of Manufacturing Processes 171. p.288-298- Abstract
Dead material zones – stationary regions of adhered material at the tool–workpiece interface – are a recurring feature in large-strain deformation processes such as metal cutting and indentation. Despite their practical significance, the mechanisms governing their initiation and evolution remain poorly understood, largely due to the difficulty of resolving local deformation events in real time. In this study, we present direct in situ evidence of dead zone formation using a high-resolution experimental framework based on ensemble-averaged digital image correlation (EADIC) and synchronized force measurements. Across three distinct metallic systems – Al6061-T6, Ti6Al4V, and Inconel 718 – we identify a consistent two-stage mechanism: (i)... (More)
Dead material zones – stationary regions of adhered material at the tool–workpiece interface – are a recurring feature in large-strain deformation processes such as metal cutting and indentation. Despite their practical significance, the mechanisms governing their initiation and evolution remain poorly understood, largely due to the difficulty of resolving local deformation events in real time. In this study, we present direct in situ evidence of dead zone formation using a high-resolution experimental framework based on ensemble-averaged digital image correlation (EADIC) and synchronized force measurements. Across three distinct metallic systems – Al6061-T6, Ti6Al4V, and Inconel 718 – we identify a consistent two-stage mechanism: (i) adhesion-induced pinning of material at the tool tip and (ii) internal shear leading to the delineation of a nascent dead zone, followed by gradual material accumulation and resulting in geometric stabilization. These stages are shown to influence chip morphology, cutting forces, and surface defect formation. The findings offer mechanistic insight into chip–tool interactions and provide a foundation for controlling dead zone behavior through process design and tool geometry.
(Less)
- author
- Gupta, Deepika ; Dawara, Vineet ; M’Saoubi, Rachid LU and Viswanathan, Koushik
- organization
- publishing date
- 2026-08
- type
- Contribution to journal
- publication status
- published
- subject
- keywords
- Dead zone formation, Deformation kinematics, In situstudies (DIC), Large strain deformation, Surface defects, Surface roughness, tool–workpiece interface, Tribology
- in
- Journal of Manufacturing Processes
- volume
- 171
- pages
- 11 pages
- publisher
- Elsevier
- external identifiers
-
- scopus:105039263410
- ISSN
- 1526-6125
- DOI
- 10.1016/j.jmapro.2026.04.075
- language
- English
- LU publication?
- yes
- id
- b894cf60-e5fa-46ba-be34-cf4e4817c861
- date added to LUP
- 2026-08-24 14:38:09
- date last changed
- 2026-08-24 14:38:41
@article{b894cf60-e5fa-46ba-be34-cf4e4817c861,
abstract = {{<p>Dead material zones – stationary regions of adhered material at the tool–workpiece interface – are a recurring feature in large-strain deformation processes such as metal cutting and indentation. Despite their practical significance, the mechanisms governing their initiation and evolution remain poorly understood, largely due to the difficulty of resolving local deformation events in real time. In this study, we present direct in situ evidence of dead zone formation using a high-resolution experimental framework based on ensemble-averaged digital image correlation (EADIC) and synchronized force measurements. Across three distinct metallic systems – Al6061-T6, Ti6Al4V, and Inconel 718 – we identify a consistent two-stage mechanism: (i) adhesion-induced pinning of material at the tool tip and (ii) internal shear leading to the delineation of a nascent dead zone, followed by gradual material accumulation and resulting in geometric stabilization. These stages are shown to influence chip morphology, cutting forces, and surface defect formation. The findings offer mechanistic insight into chip–tool interactions and provide a foundation for controlling dead zone behavior through process design and tool geometry.</p>}},
author = {{Gupta, Deepika and Dawara, Vineet and M’Saoubi, Rachid and Viswanathan, Koushik}},
issn = {{1526-6125}},
keywords = {{Dead zone formation; Deformation kinematics; In situstudies (DIC); Large strain deformation; Surface defects; Surface roughness; tool–workpiece interface; Tribology}},
language = {{eng}},
pages = {{288--298}},
publisher = {{Elsevier}},
series = {{Journal of Manufacturing Processes}},
title = {{Tracing the birth of a dead zone : Lessons from in situ analysis of tool–workpiece interactions}},
url = {{http://dx.doi.org/10.1016/j.jmapro.2026.04.075}},
doi = {{10.1016/j.jmapro.2026.04.075}},
volume = {{171}},
year = {{2026}},
}