Numerical Simulation of Machining Nickel-Based Alloys

Prete, Antonio Del; Filice, Luigino; Umbrello, Domenico

doi:10.1016/j.procir.2013.06.147

Cited by 27 publications

(16 citation statements)

References 8 publications

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“…On the other hand, in order to accurately simulate hot forging process by means of numerical techniques such as finite element method, it is important to precisely understand the constitutive equations which describe the dependence of the flow stress on the strain, strain rate and temperature. In the past two decades, many studies have been carried out to characterize the high temperature flow behaviour in IN718 [22][23][24][25][26][27][28][29][30][31][32].…”

Section: Introductionmentioning

confidence: 99%

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Flow characteristics and intrinsic workability of IN718 superalloy

Chen

Liu

et al. 2015

Materials Science and Engineering: A

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a b s t r a c tThis study focuses on deformation characteristics of superalloy IN718 by formulation of a new flow stress model and detailed evaluation of intrinsic workability through the generation of three-dimensional (3D) processing maps with the support of optical microstructural observations. Based on thermomechanical simulation tests using a Gleeble-1500 machine, the flow stress model for superalloy IN718 was built and the flow stress throughout the entire deformation process was described by a peak stress only depending on Zener-Hollomon parameter and strain. The developed model exhibited the strain softening due to dynamic recrystallisation (DRX). The intrinsic workability was further investigated by constructing 3D processing maps. The 3D processing maps described the variations of the efficiency of power dissipation and flow instability domains as a function of strain rate, temperature and strain, from which the favourite deformation conditions for thermomechanical processing of IN718 can be established.

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Section: Introductionmentioning

confidence: 99%

“…Furthermore, Zhao et al [29] proposed a dislocation density based state variable to describe the characteristic flow behaviour during hot deformation in IN718. The hardness-based flow stress model was introduced for IN718 [30]. The effect of the initial workpiece hardness was incorporated into the reference J-C equation.…”

Section: Introductionmentioning

confidence: 99%

Flow characteristics and intrinsic workability of IN718 superalloy

Chen

Liu

et al. 2015

Materials Science and Engineering: A

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“…where d is the average grain size, and a and k are two constants calibrated from literature [10][11][12]. Experimental results on cutting forces, chip morphology and temperature are used to validate the results of the orthogonal cutting simulation of Inconel 718.…”

Section: Fe Modeling Of the Orthogonal Cutting Processmentioning

confidence: 99%

“…Furthermore, a thermocouple (K-type) is also embedded between the tool-holder and tool, as shown in Figure 1. The maximum machining temperature at the tool edge location is evaluated by using inverse numerical methodology [12]. After the machining operation, the geometrical parameters of the chips (peak, valley and pitch) are observed and measured by using an optical microscope (1000x).…”

Section: Fe Modeling Of the Orthogonal Cutting Processmentioning

confidence: 99%

Numerical Simulation of Surface Modification During Machining of Nickel-based Superalloy

et al. 2015

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The main objective of this study is to implement a reliable FE model of the orthogonal machining of a Nickel based superalloy for the prediction of microstructural changes occurring during the process. A FE numerical model was properly calibrated using an iterative procedure based on the comparison between simulated and experimental results. A user subroutine was implemented in the FE code to simulate the dynamic recrystallization and consequently the grain refinement and hardness variation when orthogonal cutting of Nickel based superalloy is performed. Thus, Zener-Hollomon and Hall-Petch equations were implemented to predict the grain size and micro hardness, respectively. In addition, the depth of the affected layer was predicted using the critical strain equation. The obtained results proved the adequacy of the proposed model showing a good agreement between the simulated and the experimental results.

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“…Researches in this field mainly focus on chips and machined surfaces. Serrated chips are easily produced when machining the workpiece with high hardness and low thermophysical properties such as titanium alloys [6] and nickel-base superalloys [10]. Obvious grain refinement is noticed at the shear bands of serrated chips [6,7].…”

Section: Introductionmentioning

confidence: 99%

Evolutions of grain size and micro-hardness during chip formation and machined surface generation for Ti-6Al-4V in high-speed machining

Wang

et al. 2015

Int J Adv Manuf Technol

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Machined surface with ultrafine grained microstructure can be obtained through severe plastic deformation in high-speed machining (HSM) process. The aim of this paper is to investigate the evolution of grain size and microhardness during HSM of Ti-6Al-4V alloy using the finite element method (FEM) and user subroutine VUSDFLD of Abaqus/Explicit. Firstly, a FE model to simulate the cutting process of Ti-6Al-4V is proposed. The proposed cutting simulation model is verified by high-speed machining experiments in terms of cutting force and chip morphology. Secondly, a novel user subroutine VUSDFLD based on equations of Zener-Hollomon and Hall-Petch is developed to simulate the modifications of grain size and micro-hardness in chip formation and machined surface generation under different cutting speeds. Parameters in the equations of Zener-Hollomon and Hall-Petch are modified for Ti-6Al-4V for simulation of the change of grain size and micro-hardness during HSM. Lastly, the simulation results of the microstructure evolution in chips and machined surfaces are compared with experimental results obtained by optical microscopy, scanning electron microscopy (SEM), and measurement of micro-hardness. The comparison results show that the evolution of grain size and micro-hardness of Ti-6Al-4V in HSM can be accurately predicted by the modified Zener-Hollomon and Hall-Petch equations. This research indicates that smaller grain sizes are produced into both chips and machined surfaces due to more severe deformations with increasing of the cutting speed. The findings validate that HSM is a reliable approach to generate refined grains if proper machining parameters are selected. HSM can also be applied as a novel material test method to study the relationship between microstructure evolution and deformation parameters.

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Numerical Simulation of Machining Nickel-Based Alloys

Cited by 27 publications

References 8 publications

Flow characteristics and intrinsic workability of IN718 superalloy

Flow characteristics and intrinsic workability of IN718 superalloy

Numerical Simulation of Surface Modification During Machining of Nickel-based Superalloy

Evolutions of grain size and micro-hardness during chip formation and machined surface generation for Ti-6Al-4V in high-speed machining

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