Finite element modeling of microstructural changes in Waspaloy dry machining

Caruso, Serafino; Imbrogno, Stano; Rinaldi, Sergio; Umbrello, Domenico

doi:10.1007/s00170-016-9037-y

Cited by 22 publications

(5 citation statements)

References 25 publications

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“…It was performed on the basis of the optimization where the Deform2D was considered as ideal software in the domain of finite Modelling. Shi et al selected the deform2D software that has been proven to be the best option for meticulous analyses on machining processes in many illustrations [23]. Many researchers highly dependent on this softwareto achieve close affinity between the experimental results and the simulation values.…”

Section: Modelling Of Workpiece and Cutting Tool Using Deform2dmentioning

confidence: 99%

Investigation and finite element simulation on the MRR and tool wear of aluminium silicon alloy during turning process

Pritima¹,

Veerappan²,

L³

et al. 2022

Surf. Topogr.: Metrol. Prop.

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In this study tool wear, cutting zone temperature, cutting forces, and material removal rate (MRR) were analysed using three different coating materials during the turning of high silicon aluminium alloy. The results that are derived on coating thickness were analysed in terms of specific coating materials from the proposed numerical investigation. Feed rate was also analysed with respect to output performance on tool wear, cutting temperature, MRR, and cutting forces. Decrease of 90% wear depth on the work piece was confirmed from titanium carbide coated with 3 microns (m) coated tool and compared with Al2O3 coated tool during the comparison study between coated tools. Cutting forces were determined with proper care and close observation. The highest tool wear of 0.00461 mm was observed using Al2O3 coated tool thickness of 5 microns (m). The lowest tool wear of 0.00043 mm was observed using TiC coated tool thickness of 3 microns (m) with minimum cutting force of 74.31 N and also the highest MRR was obtained in the same. It was evident from the observation that the reduction of forces occurred using 2 microns (m) coated tool on Al2O3leading to the drastic reduction in the thickness up to 67%. The value again reduced when compared with titanium carbide tool on the work piece metal. The analysis established the minimization of tool wear, cutting force, cutting temperature due to lower feed rates. But there was an increase in case of MRR due to lower feed rates. Al2O3 coated cutting tool insert which has maximum tool wear was chosen for the experiment work and the simulations were carried out using Deform2D software. Tool wear length was compared by using SEM images and tool wear was discussed.

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Section: Modelling Of Workpiece and Cutting Tool Using Deform2dmentioning

confidence: 99%

Investigation and finite element simulation on the MRR and tool wear of aluminium silicon alloy during turning process

Pritima¹,

Veerappan²,

L³

et al. 2022

Surf. Topogr.: Metrol. Prop.

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“…The second one is a Johnson-Cook (JC) model proposed by Dong et al [10]. The subsequent model was developed by Caruso et al [11] opportunely modifying the common JC flow stress model to better consider the material deformation strengthening effects. The last one is a new JC model proposed for this research work.…”

Section: /2 4 Plastic Flo 4 Plastic Flow Str W Stress Models Ess Modelsmentioning

confidence: 99%

“…7) and XDRX is the volume fraction of the recrystallized grains (Eq. 8) [11,12]. It depends on strain (ε), critical strain (εcr) described by Eq.…”

Section: /3mentioning

confidence: 99%

Waspaloy orthogonal hard machining simulation, a comparison among different rheological models

Rinaldi¹,

Umbrello²

2021

Esaform 2021

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Nickel based superalloys, such as Waspaloy, are extensively used to manufacture components that operate under high temperature cyclic loads, because of their superior chemical and thermo-mechanical properties. In particular, these artifacts are mainly produced by shaping and/or finishing machining operations. Despite of their huge properties, these alloys show an extremely poor workability, that makes them part of the group of the so called difficult-to-cut materials. Therefore, the proper selection of the machining conditions is always challenging for the designers. In this context, predictive models represent an extremely useful tool to numerically simulate the machining process, guaranteeing a good knowledge of the material behavior under machining conditions, and avoiding expansive and time consuming experimental campaigns. Besides, the proper selection of the material rheological model is of fundamental importance in order to obtain precise and affordable results from the numerical model. In this work a Johnson-Cook based viscoplastic flow behavior model was proposed. The model was obtained from Artificial Neural Network (ANN) based interpolation techniques and validated using orthogonal machining experimental tests. Moreover, the proposed model was compared with other rheological models available from literature to benchmark their affordability and assessing their performances.

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“…This evolution can influence the hardness, thickness, and type of defects generated on the affected surface after final machining [11,34]. Only few studies have examined the relationship between microstructural alterations and cutting parameters [35,36].…”

Section: Modeling Of the Deformed Layer Thickness Evolutionmentioning

confidence: 99%

Modeling of the microstructure alteration induced by hard turning of Inconel 718

Touazine

Akab

Jahazi

et al. 2017

Int J Adv Manuf Technol

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The machining of nickel-based superalloys used for aeronautical applications generates damage, deformation and carbide cracking in machined surface and subsurface layers as a result of microstructural heterogeneities which reduce the fatigue life of aeronautic machined components. In this study, Inconel 718 was hard turned with a carbide tool using different cutting conditions according to a Roquemore 311B hybrid design of experiments (DOE) method. The main objective of the study was to model the effect of cutting parameters on the evolution of the microstructure and to accurately predict the alterations induced by machining, especially the deformed layer thickness () and the average number of cracked carbides (). The material removal rate () and the deformation power () were calculated in order to obtain a strong correlation between controlled cutting parameters and microstructure alterations. Damages were quantified using a confocal laser-digital microscope and were validated with the proposed models. These models showed a direct relation between both and with and , with good prediction at a 95% confidence interval ().

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Finite element modeling of microstructural changes in Waspaloy dry machining

Cited by 22 publications

References 25 publications

Investigation and finite element simulation on the MRR and tool wear of aluminium silicon alloy during turning process

Investigation and finite element simulation on the MRR and tool wear of aluminium silicon alloy during turning process

Waspaloy orthogonal hard machining simulation, a comparison among different rheological models

Modeling of the microstructure alteration induced by hard turning of Inconel 718

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