Modeling and Simulation of the Microstructure Evolution of 42CrMo4 Steel During Electrochemical Machining

Klocke, Fritz; Harst, Simon; Zeis, Markus; Klink, Andreas

doi:10.1016/j.procir.2017.12.082

Cited by 17 publications

(14 citation statements)

References 14 publications

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“…For high electric field strengths E-typically in the frontal machining gap-no significant changes occur. The results agree well with experimental results, therefore validating the given modeling approach [35].…”

Section: Exemplary Process Signature Componentsupporting

confidence: 87%

“…13. Based on specific material removal rates of the material phases involved and temporarily and spatially evolving local electric field strength during the process, a comprehensive modeling on the microstructural scale was carried out [34,35]. As a result, the change in the phase fraction of cementite and ferrite can be seen as a function of the maximum electric field strength as the relevant descriptive of the internal material load.…”

Section: Exemplary Process Signature Componentmentioning

confidence: 99%

“…electric field strength and change of phase fractions (PSC) for ECM acc. to [35] the desired surface integrity of workpieces. This will finally allow to reach the targeted part functionalities [36] of chemically and thermo-chemically treated parts in a defined way.…”

Section: Exemplary Process Signature Componentmentioning

confidence: 99%

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Underlying Mechanisms for Developing Process Signatures in Manufacturing

et al. 2018

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The concept of Process Signatures allows the reliable and knowledge-based prediction of material modifications (e.g., changes of hardness, residual stress, microstructure and chemical composition) researchers in the field of surface integrity, and manufacturing technologies have already been seeking for a long time. A Process Signature is based on the correlation between the internal material loads in manufacturing processes (e.g., stress, strain, temperature) and the resulting material modifications. The target of this paper is to get a comprehensive view on the development of single Process Signature Components for processes with different predominant impacts. Particularly, a mechanism-based approach leading to significant descriptives of internal material loads for a specific material modification is proposed. By this, a deeper understanding of the underlying mechanisms leading to changes of the workpiece surface layer properties caused by manufacturing processes is provided. The challenging identification of significant mechanisms and descriptives of internal material loads is highlighted for each process, and supporting measurement methods and modeling approaches are presented. Process Signatures are expected to enable the solution of the so-called inverse problem in manufacturing.

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Section: Exemplary Process Signature Componentsupporting

confidence: 87%

Section: Exemplary Process Signature Componentmentioning

confidence: 99%

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Underlying Mechanisms for Developing Process Signatures in Manufacturing

et al. 2018

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“…Klocke et al [ 24,25 ] have investigated the effect of ECM on the microstructure of ferritic–pearlitic 42CrMo4 steel in 2.5 M sodium nitrate solution. Selective dissolution of the steel with a preferred dissolution of the electrochemically less noble ferrite phase in contrast to the cementite phase was proven.…”

Section: Introductionmentioning

confidence: 99%

Impact of rim zone modifications on the surface finishing of ferritic–pearlitic 42CrMo4 using electrochemical machining

Zander

Schupp

Mergenthaler

et al. 2021

Materials & Corrosion

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The efficiency of material removal using electrochemical machining (ECM) is highly dependent on the initial rim zone modifications of the material to be processed. The influence of the rim zone modifications, such as topography and microstructure, on ECM, is investigated on ferritic–pearlitic 42CrMo4 steel by experiment and simulation. 42CrMo4 steel in two different premachining states—ground and electric discharge machined (EDM)—is subjected to a subsequent surface finishing by ECM in sodium nitrate solution. Before and after ECM, the topography and microstructure are examined using scanning electron microscopy, X‐ray diffractometer, and topography analysis methods. The electrochemical properties of the material are determined by potentiodynamic polarization. The efficiency of surface finishing by ECM is quantified by mass spectroscopic analysis (inductively coupled plasma mass spectrometry) of the process electrolyte and related to the rim zone modifications by simulation. The results reveal that the efficiency of material removal during ECM is higher for EDM than for ground 42CrMo4. This is attributed to an increased roughness of EDM 42CrMo4 and to the unfavorable electrochemical properties of the cementite phase in ground 42CrMo4.

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“…Kumar et al [19] investigated the effect of process parameters on surface roughness characteristic in electrochemical machining of EN31 tool steel using grey relation analysis. Klocke et al [20] presents a model for the prediction of microstructure evolution regarding the influence of on the surface topography for the 42CrMo4 steel during electrochemical machining. The effectiveness of surface characteristics for the design and analysis of experiments has been proven in many research works [21][22][23][24][25][26].…”

Section: Introductionmentioning

confidence: 99%

Experimental Study of Surface Characteristic in Electrochemical Machining of 35CrMo Steel

Zhang

Liu

Yue

et al. 2018

Metals

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35CrMo steel is a widely used material in machinery equipment for the petroleum industry. With the improvement of exploring technology, some particular complex features cannot be achieved with traditional processing methods. However, electrochemical machining provides a potential solution to such problems, especially in the machining of the turbine blades of turbine drilling tools, in which the surface behavior of the workpiece is an important basis for judging the machining effect. To investigate the surface behavior of 35CrMo after electrochemical machining, the electrochemical machining experiment of 35CrMo steel was conducted by a self-made experimental system. Effects of the electrolyte type, concentration, and current density on surface quality were investigated in this study. The surface characteristics of 35CrMo steel were analyzed under different current densities in three different electrolytes-NaCl, NaClO 3 and NaNO 3-with different concentrations. Based on the obtained results, an optimum machining plan was obtained. The principle of the electrolysis reaction of 35CrMo steel in NaCl, NaClO 3 and NaNO 3 electrolytes were studied as well. Experimental results showed that the best surface quality of 35CrMo steel was achieved under an NaClO 3 electrolyte concentration of 200 g/L and current density of 30 A/cm 2. The results in this paper provide a theoretical basis for the effective machining of complex parts such as downhole turbine blades.

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Modeling and Simulation of the Microstructure Evolution of 42CrMo4 Steel During Electrochemical Machining

Cited by 17 publications

References 14 publications

Underlying Mechanisms for Developing Process Signatures in Manufacturing

Underlying Mechanisms for Developing Process Signatures in Manufacturing

Impact of rim zone modifications on the surface finishing of ferritic–pearlitic 42CrMo4 using electrochemical machining

Experimental Study of Surface Characteristic in Electrochemical Machining of 35CrMo Steel

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