Cutting force based surface integrity soft-sensor when hard machining AISI 4140

Abstract

Workpiece rim zone modifications during hard machining can be explained with the high thermo-mechanical loads induced by the cutting process. The formation of White Layers with a fine-grained microstructure by dynamic recrystallization (DRX) is one of those surface modifications that can negatively affect the functionality of a machined part by changing the residual stress state and facilitating crack initiation. As a consequence, the fatigue life of the machined parts is reduced. It is therefore of great interest to understand the thermo-mechanical conditions which induce White Layers formation in order to be able to control them by in-situ measurements if necessary. For this purpose, a cutting force based Soft-Sensor is developed in this study which enables the in-process estimation of White Layer thickness. Therefore, a cutting force based analytical model is used to estimate the resulting temperature fields and correlated with validated numerical chip formation simulations. In addition, the predictions of the White Layer thickness of the analytical model are then compared using light microscopy and the results of the numerical finite element model, in which a DRX model is additionally implemented.

Machine Learning of Surface Layer Property Prediction for Milling Operations

“…Stampfer et al [56] considered cutting force measurement insufficient for the development of a soft sensor and propose further process measurands such as acoustic emission. Meurer et al [57] proposed a surface integrity sensor based on cutting force to predict white layer thickness. The predicted white layer thickness values showed deviations of more than 100% to experimental data.…”