Metallurgical Analysis of Chip Forming Process when Machining High Strength Bainitic Steels

Haddad, Fares; Lescalier, Christophe; Desaigues, Jean-Edouard; Bomont-Arzur, Anne; Bomont, Olivier

doi:10.3390/jmmp3010010

Cited by 4 publications

(2 citation statements)

References 22 publications

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“…One of the papers about microstructure influences on chip formation [14] presents results of the turning of bainite and tempered martensite structure of 42CrMo4 steel, where chip morphology and cutting forces have been analyzed. For cutting force analysis, a changing cutting depth, speed and feeding were used.…”

Section: Introductionmentioning

confidence: 99%

Modeling and Optimization of Steel Machinability with Genetic Programming: Industrial Study

Kovačić

Salihu

Gantar

et al. 2021

Metals

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In this paper, machinability influences from the start to end of final product production in a steel plant were analyzed, including chemical composition, deoxidizing agents and casting parameters, which drastically influence the macrostructure and segregation (i.e., chemical nonhomogeneity) of continuously cast and subsequently rolled material. The data (seven parameters from secondary metallurgy, four parameters from the casting process and the content of ten chemical elements) from the serial production of calcium-treated steel grades (254 batches of 25 different steel grades from January 2018 to March 2020) were used for predicting machinability. Machinability was determined based on ISO 3685:1993, where the machinability of each individual batch is represented as the cutting speed and the tool is worn out within fifteen minutes. For the prediction of these cutting speeds, linear regression and genetic programming were used. Out of 25 analyzed steel grades, 20MnV6 steel grade was the most problematic and also the most often produced. Out of 57 produced batches of 20MnVS6 steel, 23 batches had nonconforming machinability. Based on the modeling results, the steelmaking process was optimized. Consequently, 40 additional batches of 20MnV6 (from March 2020 to July 2020) were subsequently produced based on an optimized steelmaking process. In all 40 cases, the required machinability was achieved without changing other properties required by the customers.

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Section: Introductionmentioning

confidence: 99%

Modeling and Optimization of Steel Machinability with Genetic Programming: Industrial Study

Kovačić

Salihu

Gantar

et al. 2021

Metals

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“…Given their high performance under severe working conditions, via mechanical and thermal stresses and harsh chemical environments [1,2], superalloys and advanced materials have been widely used in the manufacturing of components for jet engines [2], turbochargers [3] and aerospace [4] applications. Nevertheless, these materials display difficult machinability characteristics [5,6] due to their low thermal diffusivity [2], high strain hardening [7], high chemical reactivity [8], carbide precipitation in grain boundaries [1] and high ductility [9]. Chief among these machining attributes, the high ductility of machined workpieces ordinarily leads to the formation of long continuous chips during the machining process, which negatively affects the safety, efficiency and continuity of the machining operation [10].…”

Section: Introductionmentioning

confidence: 99%

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation

2019

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Chip evacuation is a critical issue in metal cutting, especially continuous chips that are generated during the machining of ductile materials. The improper evacuation of these kinds of chips can cause scratching of the machined surface of the workpiece and worsen the resultant surface quality. This scenario can be avoided by using a properly designed chip breaker. Despite their relevance, chip breakers are not in wide-spread use in polycrystalline diamond (PCD) cutting tools. This paper presents a systematic methodology to design chip breakers for PCD turning inserts through finite element modelling. The goal is to evacuate the formed chips from the cutting zone controllably and thus, maintain surface quality. Particularly, different scenarios of the chip formation process and chip curling/evacuation were simulated for different tool designs. Then, the chip breaker was produced by laser ablation. Finally, experimental validation tests were conducted to confirm the ability of this chip breaker to evacuate the chips effectively. The machining results revealed superior performance of the insert with chip breaker in terms of the ability to produce curly chips and high surface quality (Ra = 0.51–0.56 µm) when compared with the insert without chip breaker that produced continuous chips and higher surface roughness (Ra = 0.74–1.61 µm).

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State of the art of research studies on machining processes by French research network Manufacturing’21

Wagner

2023

Int J Adv Manuf Technol

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Metallurgical Analysis of Chip Forming Process when Machining High Strength Bainitic Steels

Cited by 4 publications

References 22 publications

Modeling and Optimization of Steel Machinability with Genetic Programming: Industrial Study

Modeling and Optimization of Steel Machinability with Genetic Programming: Industrial Study

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation

State of the art of research studies on machining processes by French research network Manufacturing’21

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