Fatigue life of machined components

Pramanik, Alokesh; Dixit, Amit Rai; Chattopadhyaya, Somnath; Uddin, Md. Sharif; Dong, Yu; Basak, A.K.; Littlefair, Guy

doi:10.1007/s40436-016-0168-z

Cited by 47 publications

(27 citation statements)

References 57 publications

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“…It is well known that the machining surface integrity influences strongly the fatigue lifetime of materials, since fatigue micro-cracks initiate always at the surface [12][13][14][15][16][17]. For this reason, several studies have been dedicated to the effects of milling on fatigue behaviour of many materials, particularly aluminium and titanium alloys, and superalloys widely used to manufacture structural parts for aviation and aerospace industries [18][19][20][21][22][23][24][25].…”

Section: Introductionmentioning

confidence: 99%

Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel

Laamouri

Ghanem

Braham

et al. 2019

Int J Adv Manuf Technol

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is an open access repository that collects the work of Arts et Métiers ParisTech researchers and makes it freely available over the web where possible. This is an author-deposited version published in: https://sam.ensam.eu Handle ID: .http://hdl.handle.net/10985/18458 To cite this version :Adnen LAAMOURI, Farhat GHANEM, Chedly BRAHAM, Habib SIDHOM -Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel Abstract This paper aims to compare the influences of the two peripheral milling modes, up-milling and down-milling, on surface integrity and fatigue strength of X160CrMoV12 high-alloy steel. The experimental investigations showed an important difference between integrity of both milled surfaces. The down-milled surface is lowly work-hardened and well finished (lower roughness), but subjected to tensile residual stresses and severely damaged by folds of metal and short micro-cracks. The up-milled surface is highly work-hardened and subjected to compressive residual stresses, but poorly finished (higher roughness) and damaged by a density of micro-cavities due to carbide extraction. The results of 3-point bending fatigue tests revealed that the fatigue limit at 2 × 10 6 cycles of the up-milled state is largely higher of about 26% in comparison with the down-milled state. The effects of surface integrity induced by each milling mode on fatigue strength were evaluated using a HCF behaviour predictive approach based on Dang Van's multiaxial criterion. The predictive results estimated that the pre-existing micro-cracks play a dominant role in the fatigue strength degradation of the down-milled surface while the other surface effects seem to be lower. On the contrary, the fatigue strength of the up-milled surface is less affected by the pre-existing micro-cavities. The detrimental roughness effect (stress concentration effect) is significantly reduced by the beneficial effects of superficial hardening and compressive residual stresses. So, this study revealed that up-milling is the more appropriate mode for a better surface integrity towards fatigue strength of X160CrMoV12 steel than the down-milling mode.

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Section: Introductionmentioning

confidence: 99%

Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel

Laamouri

Ghanem

Braham

et al. 2019

Int J Adv Manuf Technol

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“…The diverse failure modes in addition to inborn anisotropies, complicated stress fields, and non-linear properties of composites restrict the understanding of fatigue properties of metal matrix composites (MMCs) (Basak, Pramanik, & Islam, 2013;Paknia, Pramanik, Dixit, & Chattopadhyaya, 2016). Generally, fatigue tests of materials are performed on specimens fabricated with near ideal surface finish such as after polishing which may remove surface defects/inhomogeneity that might reduce the overall fatigue performance (Pramanik, Dixit, et al, 2017). However, from practical applications point of view, it is very expensive as well as difficult to fabricate polished/surface defect free parts towards that.…”

Section: Introductionmentioning

confidence: 99%

“…Fatigue strength of machined components depends on workpiece material, machining type and conditions. So far, the information on this area is available only for very few alloys such as, titanium, steel, aluminium and nickel alloys which include few isolated machining parameters as reviewed by Hakami et al, (Hakami, Pramanik, & Basak, 2016) and Pramanik et al(Pramanik, Dixit, et al, 2017). Pramanik et al, (Pramanik, Islam, et al, 2017) investigated the contribution of different parameters on fatigue life of machined MMC components.…”

Section: Introductionmentioning

confidence: 99%

Fracture and fatigue life of Al-based MMCs machined at different conditions

Pramanik

Basak

2018

Engineering Fracture Mechanics

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This study investigates fracture and fatigue performance of metal matric composites (MMCs) without any reinforcement and, 0.7 and 13 µm particle (10 vol. %) reinforced which were machined at different feeds and speeds. Fractured surface as well as fatigue generated cracks were investigated in details. The effect of interactions among input machining parameters with their variations on fatigue life has also been analysed. It was found that fatigue cracks don't follow machining traces. Moreover, the cracks are almost straight and sharp when reinforcing particles are smaller but change the course, and surface along the crake is highly damaged when the reinforced particles are bigger. The appearance of fractured surfaces of the samples are very similar regardless of particles size and machining conditions. Though compressive residual stress is generated on the machined MMC surfaces, fatigue life of MMCs are much shorter than that of corresponding matrix material due to the fracture and detachment of reinforcing particles from matrix. Fatigue life has an initial decreasing trend with the rise of feed-rate and then it increases significantly with further increase of feed-rate in the absence of particles machine at low speed. However, fatigue life remains almost constant with the increase of feed-rate for larger particle reinforced MMC machined at high speed. With the increase of speed, opposite trends on fatigue life were noticed for MMCs and matrix material when machined at low and high feeds, respectively. The larger reinforced particles reduces the fatigue life of machined specimens at every interacting combinations of parameters.

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“…The tensile residual stresses can increase the service stresses which can lead to the premature failure of the components. 3,4 The generation mechanism of the machined residual stress has been studied by several researchers. Outeiro et al 5 studied the residual stress induced by turning machining, in which the particular attention was paid to the effect of the cutting parameters, such as the cutting speed, the feed rate and the depth of cut.…”

Section: Introductionmentioning

confidence: 99%

Effect of cutting parameters on the residual stress distribution generated by pocket milling of 2219 aluminum alloy

Sun

Lin

et al. 2018

Advances in Mechanical Engineering

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This work describes the experimental investigation of the residual stress distribution in the square pocket milling of 2219 aluminum alloy. The results reveal that the axial depth of cut is the most important factor influencing the residual stress distribution of the machined pocket surface, and the more tensile stress states are found with the increase in axial cutting depth due to the thermal deformation. The dominant mechanical deformation at all spindle speeds tends to produce the compressive residual stress. Altered feed rate and radial depth of cut show little changes in the residual stress distributions and the average values. In addition, the pattern of residual stress distribution of the square pocket surface is dramatically changed and the more tensile stresses are produced as the milling operation further proceeds. From this investigation, it is suggested to shorten the cutting time by raising the cutting parameters such as the feed rate and the radial depth of cut to achieve the compressive stress and the good surface roughness.

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Fatigue life of machined components

Cited by 47 publications

References 57 publications

Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel

Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel

Fracture and fatigue life of Al-based MMCs machined at different conditions

Effect of cutting parameters on the residual stress distribution generated by pocket milling of 2219 aluminum alloy

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