FEM-simulation of machining induced surface plastic deformation and microstructural texture evolution of Ti-6Al-4V alloy

Li, Anhai; Pang, Jiming; Zhao, Jun; Zang, Jianbing; Wang, Fuzeng

doi:10.1016/j.ijmecsci.2017.02.014

Cited by 60 publications

(28 citation statements)

References 23 publications

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“…The study carried out by Tajalli et al [40] showed that the initial grain orientation affects the morphology of the chip and the cutting forces. The recent study carried out by Li et al [41] proves the capability of this kind of modeling for an accurate prediction of the deformed material texture.…”

Section: Introductionmentioning

confidence: 88%

Orthogonal micro-cutting modeling of the Ti17 titanium alloy using the crystal plasticity theory

Ayed

Robert

Germain

et al. 2017

Finite Elements in Analysis and Design

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The development of computation means has allowed the simulation of complex mechanical problems. The first simulations of manufacturing processes at the microstructure scale, namely in the field of machining, have recently emerged. In this study, and on the basis of previous research, a novel approach to machining simulation is proposed. A crystal plasticity behavior law has thus been implemented and its parameters have been identified, for each of the two phases constituting the material. This is achieved through experimental tests conducted under extreme conditions of temperature and strain rates. Numerical models are composed of grains in the form of Voronoï cells. Random crystal orientations have also been assigned to each grain. This has subsequently allowed the simulation of the machining process. Access to local physical parameters such as crystal orientations, their evolution and phase transition thus presents a major breakthrough in this field.

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Section: Introductionmentioning

confidence: 88%

Orthogonal micro-cutting modeling of the Ti17 titanium alloy using the crystal plasticity theory

Ayed

Robert

Germain

et al. 2017

Finite Elements in Analysis and Design

View full text Add to dashboard Cite

show abstract

“…However, indispensable hardware is needed for this method. So the modeling for machined surface microstructure has attracted wide attention [65][66][67][68][69]. Unfortunately, few research works focused on the milling process are found.…”

Section: Machined Surface Metallurgy Characteristicmentioning

confidence: 99%

Part Functionality Alterations Induced by Changes of Surface Integrity in Metal Milling Process: A Review

et al. 2018

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It has been proved that surface integrity alteration induced by machining process has a profound influence on the performance of a component. As a widely used processing technology, milling technology can process parts of different quality grades according to the processing conditions. The different cutting conditions will directly affect the surface state of the machined parts (surface texture, surface morphology, surface residual stress, etc.) and affect the final performance of the workpiece. Therefore, it is of great significance to reveal the mapping relationship between working conditions, surface integrity, and parts performance in milling process for the rational selection of cutting conditions. The effects of cutting parameters such as cutting speed, feed speed, cutting depth, and tool wear on the machined surface integrity during milling are emphatically reviewed. At the same time, the relationship between the machined surface integrity and the performance of parts is also revealed. Furthermore, problems that exist in the study of surface integrity and workpiece performance in milling process are pointed out and we also suggest that more research should be conducted in this area in future.

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“…Moreover, during high-speed machining processes, microstructures evolve differently from the conventional cutting conditions, and this difference of material behavior at the micro-scale can finally influence the mechanical response at the macro-scale. Meanwhile, Yang and Liu [4] presented a method that uses milling to modify the microstructure of machined surfaces and obtain the desired mechanical behaviors for components, and Li et al [5] pointed out that the mechanical and physical properties of machined parts could be changed due to the microstructure evolution as well. Shyha et al [6] also found that the microstructure alteration in machined surfaces is influenced by cutting speeds and chip formation processes during milling of the Ti6Al4V alloy, which finally influences the performance of the components.…”

Section: Introductionmentioning

confidence: 99%

Effects of Dislocation Density Evolution on Mechanical Behavior of OFHC Copper during High-Speed Machining

Liu

Jun

et al. 2019

Materials

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This paper aims at investigating the change in material behavior induced by microstructure evolution during high-speed machining processes. Recently, high-speed machining has attracted quite a lot of interest from researchers due to its high efficiency and surface quality in machining large-scale components. However, the material behavior could change significantly at high-cutting speeds compared to the conventional cutting conditions, including their microstructure and t mechanical response. This is due to the basic physics of material at microscopic levels with high strain, high strain rates, and high temperatures. In this study, the dislocation density-related microstructure evolution process and mechanical behavior of OFHC (Oxygen-free high-conductivity) copper in high-speed machining with speeds ranging from 750 m/min to 3000 m/min are investigated. SEM (Scanning Electron Microscope) and advanced EBSD (Electron Backscattered Diffraction) techniques are used to obtain high-quality images of the microstructures and analyze the dislocation density and grain size evolution with different cutting speeds. Moreover, as material plasticity is induced by the motion of dislocations at micro-scales, a dislocation-density based (DDB) model is applied to predict strain-stress and microstructure information during the cutting process. The distributions of dislocation densities, both statistically stored dislocations (SSDs) and geometrically necessary dislocations (GNDs), are obtained through simulation and experimentation, respectively. The results show that the fluctuation in the cutting forces at high cutting speeds is induced by the specific evolution and distribution of the dislocation density under high strain-rates, and the periodical distribution of sub-surface and fracture behavior during chip separation, which are also found to be influenced by the evolution of the dislocation density.

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FEM-simulation of machining induced surface plastic deformation and microstructural texture evolution of Ti-6Al-4V alloy

Cited by 60 publications

References 23 publications

Orthogonal micro-cutting modeling of the Ti17 titanium alloy using the crystal plasticity theory

Orthogonal micro-cutting modeling of the Ti17 titanium alloy using the crystal plasticity theory

Part Functionality Alterations Induced by Changes of Surface Integrity in Metal Milling Process: A Review

Effects of Dislocation Density Evolution on Mechanical Behavior of OFHC Copper during High-Speed Machining

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