Finite element modelling of microstructural changes in dry and cryogenic machining <i>AISI 52100</i> steel

Umbrello, Domenico; Caruso, Serafino; Imbrogno, Stano

doi:10.1080/02670836.2015.1104085

Cited by 22 publications

(14 citation statements)

References 30 publications

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“…The Zener-Hollomon parameter-based empirical relationship was calibrated using the experimentally measured grain size. Then, it was embedded in a two-dimensional (2D) FE analysis to simulate the change of grain size during turning of AA7075-T651 Alloy with cutting speed of 180-720 m/min [20,21], Inconel 718 alloy [22], AZ31B Mg alloy [23], and AISI 52100 steel [24]. However, a physics-based grain refinement model is critically needed to better understand the change of grain size during cryogenic machining of AZ31B Mg alloy.…”

Section: Introductionmentioning

confidence: 99%

Enhanced Surface Integrity From Cryogenic Machining of AZ31B Mg Alloy: A Physics-Based Analysis With Microstructure Prediction

Shen

Ding

et al. 2017

J. Manuf. Sci. Eng

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The use of magnesium (Mg) alloy has been continuously on the rise with numerous expanded application in transportation/aerospace industries due to their lightweight and other areas, such as biodegradable medical implants. It was shown recently that machining can be used to improve the functional performance of Mg-based products/components, such as corrosion resistance, through engineered surface integrity. In this paper, the behavior of AZ31B Mg alloy in cryogenic machining was discussed firstly. The surface integrity can be significantly improved by introducing the ultrafine grained (UFG) layer due to the severe plastic deformation (SPD) effect during cryogenic machining. The mechanisms of microstructure evolution and plastic deformation were analyzed based on the experimental findings in literature. A physics-based constitutive model involving material plasticity and grain refinement is developed based on both slip and twinning mechanisms and successfully implemented in a finite-element (FE) analysis with multiple cutting passes to predict the microstructure evolution by nanocrystalline grain refinement and other improvement of the surface integrity in the cryogenic machining of AZ31B Mg alloy. With a more quantitative assessment, the FE model results are further discussed for grain refinement, changes in microhardness, residual stresses, and slip/twinning mechanism with the apparent SPD taking place due to rapid cryogenic cooling.

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Section: Introductionmentioning

confidence: 99%

Enhanced Surface Integrity From Cryogenic Machining of AZ31B Mg Alloy: A Physics-Based Analysis With Microstructure Prediction

Shen

Ding

et al. 2017

J. Manuf. Sci. Eng

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“…5*HRC-300 The physical events influencing the mechanical properties, were predicted by implementing a user subroutine with the empirical relationships of Zener-Hollomon (Z-H) parameter for grain refinement and Hall-Petch (H-P) equation for hardness evolution [22]. In particular, all the constants related to DRX and hardness changes were calibrated for SAE 8620 steel following the calibration procedure reported in [26]. In particular, the newly developed FE model is able to predict thermal and mechanical events during hard machining, and to show, by their single contribution, when the microstructural changes are mainly thermally or mechanically induced.…”

Section: Numerical Modelmentioning

confidence: 99%

Finite Element Modeling of Microstructural Changes in Hard Machining of SAE 8620

et al. 2019

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Surface and subsurface microstructural characterization after machining operations is a topic of great interest for both academic and industrial research activities. This paper presents a newly developed finite element (FE) model able to describe microstructural evolution and dynamic recrystallization (DRX) during orthogonal hard machining of SAE 8620 steel. In particular, it predicts grain size and hardness variation by implementing a user subroutine involving a hardness-based flow stress and empirical models. The model is validated by comparing its output with the experimental results available in literature at varying the cutting speed, insert geometry and flank wear. The results show a good ability of the customized model to predict the thermo-mechanical and microstructural phenomena taking place during the selected processes.

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“…3 Many researchers have examined the cryogenic machining process with experimental [4][5][6] and numerical methods. 7 The finite element method (FEM) has been the most frequently used numerical method for cutting simulations. Most of the FEM simulations pointed to obtaining the temperature variation, 8 residual strain and stress, 9 and chip deformation and predict the cutting force of the machining.…”

Section: Introductionmentioning

confidence: 99%

High-speed cryogenic machining of the carbon nanotube reinforced nanocomposites: Finite element analysis and simulation

Pashaki

Pouya

Maleki

2017

Proceedings of the Institution of Mechanical Engineers, Part C:

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In this paper, a new approach for evaluating the cryogenic machining process of the carbon nanotube reinforced aluminum matrix composites is developed based on finite element method. Finite element modeling in commercial code ABAQUS/Explicit was used to simulate high-speed machining of carbon nanotube reinforced composites under dry and cryogenic conditions, where different parameters (carbon nanotubes loading and the cutting speed) were investigated. The matrix phases are given a Johnson–Cook failure criterion. For considering more realistic assumptions, mechanical and thermal properties of the materials are assumed as a function of temperature. Results shown that at the cutting velocity of 60 m/s, cryogenic cooling has caused decrease of workpiece plastic strain by 12% in comparison with the dry cooling. The model can be used to study the effect of weight fraction, orientation, and length of the carbon nanotubes on the manufacturing of the nanocomposites.

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Finite element modelling of microstructural changes in dry and cryogenic machining AISI 52100 steel

Cited by 22 publications

References 30 publications

Enhanced Surface Integrity From Cryogenic Machining of AZ31B Mg Alloy: A Physics-Based Analysis With Microstructure Prediction

Enhanced Surface Integrity From Cryogenic Machining of AZ31B Mg Alloy: A Physics-Based Analysis With Microstructure Prediction

Finite Element Modeling of Microstructural Changes in Hard Machining of SAE 8620

High-speed cryogenic machining of the carbon nanotube reinforced nanocomposites: Finite element analysis and simulation

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