FEM-simulation of machining induced nanocrystalline surface layers in steel surfaces prepared for tribological applications

Ambrosy, Florian; Zanger, Frederik; Schulze, Volker

doi:10.1016/j.cirp.2015.04.063

Cited by 28 publications

(8 citation statements)

References 22 publications

(27 reference statements)

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“…In regions of the material where a threshold strain for recrystallization is achieved, the recrystallized grain size is determined according to an empirical relationship relating initial grain size, the Zener-Hollomon parameter, and material constants. This approach has been utilized by a number of authors, including Caruso et al [43] for AISI 52100, Pu et al [179] for MgAZ31B, Rotella and Umbrello [188] for Ti-6Al-4V, M'Saoubi et al [150] for advanced nickel based superalloys (Inconel 718, Wasapaloy, Udimet 720 and RR1000), Jafarian et al [119] for Inconel 718, Ambrosy et al [2] for AISI 4140. As an example, the results for Ti-6Al-4V shown in Fig.…”

Section: Microstructure Models For Machiningmentioning

confidence: 99%

Advances in material and friction data for modelling of metal machining

et al. 2017

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Section: Microstructure Models For Machiningmentioning

confidence: 99%

Advances in material and friction data for modelling of metal machining

et al. 2017

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“…Thus, it is generally accepted that white layers consists of nanocrystalline structures, which develop through dynamic recrystallization and grain subdivision through severe plastic deformation [13]. Depending on the application, white layers may become beneficial because of their positive influence on tribological properties [14]. The grain size within the white layer was analyzed with FIB and SEM.…”

Section: Resultsmentioning

confidence: 99%

Analysis of surface integrity in machining of AISI 304 stainless steel under various cooling and cutting conditions

Klocke¹,

Döbbeler²,

Lung³

et al. 2018

AIP Conference Proceedings

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Recent studies have shown that machining under specific cooling and cutting conditions can be used to induce a nanocrystalline surface layer in the workspiece. This layer has beneficial properties, such as improved fatigue strength, wear resistance and tribological behavior. In machining, a promising approach for achieving grain refinement in the surface layer is the application of cryogenic cooling. The aim is to use the last step of the machining operation to induce the desired surface quality to save time-consuming and expensive post machining surface treatments. The material used in this study was AISI 304 stainless steel. This austenitic steel suffers from low yield strength that limits its technological applications. In this paper, liquid nitrogen (LN2) as cryogenic coolant, as well as minimum quantity lubrication (MQL), was applied and investigated. As a reference, conventional flood cooling was examined. Besides the cooling conditions, the feed rate was varied in four steps. A large rounded cutting edge radius and finishing cutting parameters were chosen to increase the mechanical load on the machined surface. The surface integrity was evaluated at both, the microstructural and the topographical levels. After turning experiments, a detailed analysis of the microstructure was carried out including the imaging of the surface layer and hardness measurements at varying depths within the machined layer. Along with microstructural investigations, different topological aspects, e.g., the surface roughness, were analyzed. It was shown that the resulting microstructure strongly depends on the cooling condition. This study also shows that it was possible to increase the micro hardness in the top surface layer significantly.

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“…Zener-Hollomon model is an empirical model for the prediction of dynamically recrystallized grain size. A detailed review of this model is given in literature [18,24]. Briefly, the Zener-Hollomon parameter Z H gives the relation between the working temperature and the equivalent plastic strain rate, which can be calibrated by performing compression tests at different temperatures and strain rates.…”

Section: Zener-hollomon Modelmentioning

confidence: 99%

“…whereε p denotes the equivalent plastic strain rate, Q in J stands for the activation energy, R in J/mol/K is the universal gas constant and T in K represents the current temperature. The dynamically recrystallized grain size d DRX in µm can be calculated according to [18,24] as follows,…”

Section: Zener-hollomon Modelmentioning

confidence: 99%

“…In a separate study, Ambrosy et al implemented the Zener-Hollomon approach in Abaqus/Implicit with user-defined continuous re-meshing algorithm to model nanocrystalline grains in orthogonal cutting of AISI 4140 steel [24]. They revealed that the grain refinement and thickness of DRX-layer increase with the increasing relative roundness r β /h, which is the ratio of cutting edge radius r β to undeformed chip thickness h.…”

Section: Introductionmentioning

confidence: 99%

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Modelling of Grain Size Evolution with Different Approaches via FEM When Hard Machining of AISI 4140

Tekkaya

Meurer

Münstermann

2020

Metals

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Thermo-mechanical loads during hard turning lead to the formation of so-called White Layers on the machined surface. Characterized by a very fine microstructure and high hardness, White Layers have a negative effect on the fatigue life of a component. The fundamental mechanism for the White Layer formation is the dynamic recrystallization (DRX). Therefore, in the current work, two different DRX models, Helmholtz free energy and Zener-Hollomon, are implemented into Abaqus/Explicit to predict the thickness of the White Layer when hard turning quenched/tempered AISI 4140 and the results are compared with each other. For the simulation of the machining process a Finite Element Method (FEM) model based on the Coupled-Eulerian-Lagrangian (CEL) method is built up. Although both DRX models achieved a very good match between predicted and measured White Layer thickness and grain size evolution on the workpiece rim zone, the Zener-Hollomon model produced more closer agreement.

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FEM-simulation of machining induced nanocrystalline surface layers in steel surfaces prepared for tribological applications

Cited by 28 publications

References 22 publications

Advances in material and friction data for modelling of metal machining

Advances in material and friction data for modelling of metal machining

Analysis of surface integrity in machining of AISI 304 stainless steel under various cooling and cutting conditions

Modelling of Grain Size Evolution with Different Approaches via FEM When Hard Machining of AISI 4140

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