Analytical modeling of cutting forces considering material softening effect in laser-assisted milling of AerMet100 steel

Zhang, Hang; Zeng, Haohao; Yan, Rong; Wang, Wei; Peng, Fangyu

doi:10.1007/s00170-020-06518-w

Cited by 16 publications

(8 citation statements)

References 31 publications

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“…A computer program in Matlab 2018a is developed to simulate the proposed model. The Johnson-Cook constants of AerMet100 steel are presented in Table 4 [30]. The dislocationevolution-rate control parameters α * , β * and k 0 are determined by the stress-strain relation [31] and set as 0.8, 0.28 and 2.9, respectively.…”

Section: Resultsmentioning

confidence: 99%

“…The workpiece material used in this study is AerMet100 steel. The main chemical compositions (wt.%) and material properties of AerMet100 steel are shown in Table 1 [29] and Table 2 [30], respectively. The metallographic morphology of AerMet100 steel is shown in Figure 6.…”

Section: Materials and Machining Processmentioning

confidence: 99%

“…For the sake of comparison, the two microhardness units are unified by the formula 1 GPa = 102 HV [32]. The microhardness of the AerMet100 steel matrix is 370 HV (3.63 GPa) [30]. The microhardness of martensite and austenite are 571 HV (5.6 GPa) and 190 HV (1.863 GPa), respectively [23].…”

Section: Microhardnessmentioning

confidence: 99%

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A Multiphysics Model for Predicting Microstructure Changes and Microhardness of Machined AerMet100 Steel

et al. 2022

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The machined-surface integrity plays a critical role in corrosion resistance and fatigue properties of ultra-high-strength steels. This work develops a multiphysics model for predicting the microstructure changes and microhardness of machined AerMet100 steel. The variations of stress, strain and temperature of the machined workpiece are evaluated by constructing a finite-element model of the orthogonal cutting process. Based on the multiphysics fields, the analytical models of phase transformation and dislocation density evolution are built up. The white layer is modeled according to the phase-transformation mechanism and the effects of stress and plastic strain on real phase-transformation temperature are taken into consideration. The microhardness changes are predicted by a model that accounts for both dislocation density and phase-transformation evolution processes. Experimental tests are carried out for model validation. The predicted results of cutting force, white-layer thickness and microhardness are in good agreement with the measured data. Additionally, from the proposed model, the correlation between the machined-surface characteristics and processing parameters is established.

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Section: Resultsmentioning

confidence: 99%

Section: Materials and Machining Processmentioning

confidence: 99%

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A Multiphysics Model for Predicting Microstructure Changes and Microhardness of Machined AerMet100 Steel

et al. 2022

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“…The external power is converted into deformation energy in the cutting process. At the same time, the heat is not easy to release, causing the tool and workpiece material temperature rise, resulting in material softening [7]. On the other hand, with the increase in strain, the material work hardening occurs.…”

Section: Introductionmentioning

confidence: 99%

Dynamic Mechanical Properties and Modified Johnson-Cook Model Considering Recrystallization Softening for Nickel-Based Powder Metallurgy Superalloys

Ling,

Ren,

Wang

et al. 2024

Materials

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The material undergoes high temperature and high strain rate deformation process during the cutting process, which may induce the dynamic recrystallization behavior and result in the evolution of dynamic mechanical properties of the material to be machined. In this paper, the modified Johnson-Cook (J-C) model for nickel-based powder metallurgy superalloy considering dynamic recrystallization behavior in high strain rate and temperature is proposed. The dynamic mechanical properties of the material under different strain rates and temperature conditions are obtained by quasi-static compression test and split Hopkinson pressure bar (SHPB) test. The coefficients of the modified J-C model are obtained by the linear regression method. The modified model is verified by comparison with experimental and model prediction results. The results show that the modified J-C model proposed in this paper can accurately describe the mechanical properties of nickel-based powder metallurgy superalloys at high temperatures and high strain rates. This provides help for studying the cutting mechanism and finite element simulation of nickel-based powder metallurgy superalloy.

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“…Ultra-precision fly grooving (UPFG) is widely regarded as a promising technology to fabricate micro/nano-structured functional surfaces, due to its ability to achieve submicron form accuracy and nanometric surface roughness [1,2]. To promote the widespread application of UPFG, it is of great importance to investigate the efficient modelling methods of the cutting forces, as the prediction of cutting force is the premise of optimizing cutting parameters [3], understanding the tool-workpiece interactions [4] and monitoring tool wear [5]. Besides, cutting force model is the basis for some innovative machining technologies, such as forced-controlled servo cutting, in which cutting force serves as the feedback signal of the tool servo motion to improve the machining accuracy of freeform surfaces.…”

Section: Introductionmentioning

confidence: 99%

Analytical modelling of cutting forces in ultra-precision fly grooving considering effects of trans-scale chip thickness variation and material microstructure

Sun

et al. 2021

Int J Adv Manuf Technol

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Although ultra-precision fly grooving (UPFG) is widely applied to fabricate micro-structured surfaces, few studies have focused on the cutting force model of UPFG. The unique kinematics of UPFG leads to the trans-scale variation of undeformed chip thickness from nanoscale to microscale, in which case the influence of material microstructure and size effect is prominent. This study proposes an analytical cutting force model for UPFG with full consideration of the kinematics, chip formation mechanism, material microstructure, material elastic recovery, size effect and tool geometry. Specifically, by correlating micro-forming theory to crystal plastic theory, a hybrid slip-line model (HSLM) is developed to determine the flow stress in primary deformation zone, which can quantify the influence of size effect and microstructure, such as grain size, grain boundary, dislocation density and crystal anisotropy, on flow stress. Then, the normal cutting force and frictional cutting force are estimated by analyzing the stress distribution and frictional states at tool-chip interface. The rubbing force induced by material elastic recovery is determined based on indentation theory. Finally, the models are experimentally validated by fly cutting of polycrystalline copper with different machining parameters, and it is also demonstrated that the proposed HSLM can capture the periodic transformation of cutting mechanism in UPFG from ploughing (compressive stress) to shearing (tensile stress) with tool rotation.

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Analytical modeling of cutting forces considering material softening effect in laser-assisted milling of AerMet100 steel

Cited by 16 publications

References 31 publications

A Multiphysics Model for Predicting Microstructure Changes and Microhardness of Machined AerMet100 Steel

A Multiphysics Model for Predicting Microstructure Changes and Microhardness of Machined AerMet100 Steel

Dynamic Mechanical Properties and Modified Johnson-Cook Model Considering Recrystallization Softening for Nickel-Based Powder Metallurgy Superalloys

Analytical modelling of cutting forces in ultra-precision fly grooving considering effects of trans-scale chip thickness variation and material microstructure

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