1,721,037 research outputs found
Finite Element Modeling of Microstructural Changes in Turning of AA7075-T651 Alloy and Validation
Full text linkThe surface characteristics of a machined product strongly influence its functional performance. During machining, the grain size of the surface is frequently modified, thus the properties of the machined surface are different to that of the original bulk material. These changes must be taken into account when modeling the surface integrity effects resulting from machining. In the present work, grain size changes induced during turning of AA 7075-T651 (160 HV) alloy are modeled using the Finite Element (FE) method and a user subroutine is implemented in the FE code to describe the microstructural change and to simulate the dynamic recrystallization, with the consequent formation of new grains. In particular, a procedure utilizing the Zener-Hollomon and Hall-Petch equations is implemented in the user subroutine to predict the evolution of the material grain size and the surface hardness when varying the cutting speeds (180 - 720 m/min) and tool nose radii (0.4 - 1.2 mm). All simulations were performed for dry cutting conditions using uncoated carbide tools. The effectiveness of the proposed FE model was demonstrated through its capability to predict grain size evolution and hardness modification from the bulk material to machined surface. The model is validated by comparing the predicted results with those experimentally observed
Fatigue life of machined Ti6Al4V alloy under different cooling conditions
No full textThis paper presents an extensive experimental study on the influence of machining parameters and cooling conditions on the overall fatigue life of a titanium component. In particular, dry, minimum quantity lubrication, cryogenic and high-pressure air jet were compared as cooling/lubrication strategies for the finishing operation. The obtained dog-bone cylindrical fatigue specimens were tested under uniaxial pull–pull cyclic loading in the high cycle fatigue range. An analytical model is proposed to predict the high cycle fatigue strength for the material under investigation demonstrating its effectiveness to reduce the number of tests needed
The effects of cryogenic cooling on surface integrity in hard machining: A comparison with dry machining
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Inverse analysis procedure to determine flow stress and friction data for finite element modeling of machining
No full textThis paper describes an inverse procedure to determine the constitutive constants and the friction conditions in the machining processes using Finite Elements (FE) simulations. In general, the FE modeling of machining processes is an effective tool to analyze the materials machinability under different cutting conditions. However, the use of reliable rheological and friction models represents the basis of a correct numerical investigation. The presented inverse procedure was based on the numerical results obtained using a commercial FE code and was developed considering a specific optimization problem, in which the objective functions that have to be minimized is the experimental/numerical error. This problem was performed by a routine developed in a commercial optimization software. In order to verify the goodness and the robustness of the methodology, it was applied on a Super Duplex Stainless Steel (SDSS) and on an Austenitic Stainless Steel (AUSS) orthogonal machining processes. This work, then, was focused on the identification of the Johnson-Cook (JC) coefficients (A,B,C, n and m) and on the calibration of a Coulomb friction model, in the specific cases of the SAF2507 SDSS and of an AISI 316 Based AUSS Alloy (AISI 316 ASBA). The identification phases were performed considering forces and temperatures experimental data, collected in two specific experimental tasks in which different orthogonal cutting tests were carried out under different cutting parameters conditions
Wear Modeling in Mild Steel Orthogonal Cutting when using Uncoated Carbide Tools
No full textWear prediction in machining has been recently studied by FEM although the use of numerical methods for such applications is still a very challenging research issue. In fact, wear phenomenon involves many aspects related to process mechanics which require a very accurate modelling. In other words, only a very punctual code set-up can help the researchers in order to obtain consistent results in FE analysis. The high relative velocity between chip and tool requires effective material models as well as friction modelling at the interface. Moreover the prediction of temperature distribution is another critical task; in the paper some different procedures are discussed. Subsequently a wear model is presented and calibrated in order to obtain a suitable tool to be implemented in a FE code with the aim to describe the wear evolution during the simulation process. A proper designed experimental campaign supplied some reference data for model set-up and verify in the practical application. All these aspects are carefully discussed in the pape
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