Modeling of White and Dark Layer Formation in Hard Machining of Aisi 52100 Bearing Steel

Umbrello, Domenico; Jayal, Anshu Dhar; Caruso, Serafino; Dillon, O. W.; Jawahir, I.S.

doi:10.1080/10910340903586525

Cited by 58 publications

(27 citation statements)

References 10 publications

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“…Furthermore, white layers are also experimentally observed on both edges of the generated chip, where the lower edge white layer is significantly thinner than the upper one, cf. [26]. This is in good accordance with the predicted temperature distribution in Fig.…”

Section: Approachsupporting

confidence: 91%

“…affected by phase transformation effects, commonly referred to as white layers, whereas the underlying bulk material keeps its original phase distribution, which is wellknown from various experimental investigations, see e.g. [5,[26][27][28]. Secondly, the softening behaviour causes a localization of the heating effects in the chip material in the primary and secondary shear zone, driven by plastic dissipation and friction, respectively.…”

Section: Approachmentioning

confidence: 99%

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Evaluation of different approaches for modeling phase transformations in machining simulation

Schulze

Uhlmann

Mahnken

et al. 2015

Prod. Eng. Res. Devel.

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Presently, the main mechanism for phase transformations in machining of steels is not absolutely clear and is still subject to research. This paper presents, three different approaches for modeling phase transformations during heating in machining operations. However, the main focus lies on two methods which can be classified into a stress related method and a thermal activation related method for the description of austenitization temperature. Both approaches separately showed very good agreements in the simulations compared to the experimental validation but were never compared in a simulation. The third method is a precalculated phase landscape assigning the transformation results based on a micro-mechanically motivated constitutive model to the workpiece in dependence on the temperature and strain history. The paper describes all three models in detail, and the results are also presented and discussed.

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Section: Approachsupporting

confidence: 91%

Section: Approachmentioning

confidence: 99%

Evaluation of different approaches for modeling phase transformations in machining simulation

Schulze

Uhlmann

Mahnken

et al. 2015

Prod. Eng. Res. Devel.

View full text Add to dashboard Cite

show abstract

“…From a more physics based ground, an analytical model is proposed by Chou and Song [23] to calculate the white layer thickness in the orthogonal turning of hardened steel. More specifically, Umbrello et al [24] called the phase transformation layer as the dark layer on the machining surface of AISI 51200 steel. A finite element analysis (FEA) model is developed for the prediction of both white layer and dark layer on the machined surface.…”

Section: In 100mentioning

confidence: 99%

Material microstructure affected machining: a review

2017

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-The machining induced material microstructure evolution path is determined from the temperature and mechanical loading history. Inversely, the machining forces and machined part surface integrity are dependent on the material microstructure attributes. Most of the previous research work with a microstructure consideration in machining stays largely on the experimental observation stage. A comprehensive thermal-mechanical-microstructure coupled machining process modeling framework is still missing. This paper reviews the recent research work on the material microstructure evolution in the context of machining components. The material microstructure property change on the workpiece material in the machining process are analyzed. The effects of material microstructure evolution on workpiece mechanical properties and surface integrity are investigated. It is concluded that a physical based material microstructure affected machining model is needed for the machining process optimization.

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“…It is worthwhile mentioning that during recent years, several other research works have been developed in 3D [8,19,24,25,66] showing the remarkable future possibilities of FEM of chip formation processes.…”

Section: State Of the Art In Finite-element Models Of Hard Turningmentioning

confidence: 99%

“…Hard turning and grinding processes create different surface microgeometry [8]. With an increasing surface roughness, the influences of the microgeometrical valleys obtained in turning acquire more relevance with regard to fatigue life.…”

Section: Introductionmentioning

confidence: 99%

Finite-element Modeling and Simulation

Arrazola

2011

Machining of Hard Materials

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This chapter deals with the finite-element method (FEM) of hard machining, mainly turning (two-and three-dimensional (3D)). Results about the influence of working conditions and tool geometry (cutting-edge finishing) on tool forces, temperatures, and stresses when machining AISI 52100 steel are presented. In addition, information about residual stresses obtained through 3D FEM analysis is shown. The aim of the chapter is to demonstrate the possibilities of FEM for understanding the chip formation process in hard turning and to show its capabilities in areas like tool insert design and prediction of the surface state of the machined workpiece. First, a brief summary of the state of the art on hard machining is presented. Then FEM capabilities and limitations are shown. After that, results of process simulations will be provided and compared with those obtained in the literature. Finally, overall conclusions are pointed out and future research direction is discussed. IntroductionHard turning has become a relevant manufacturing process in producing finished components that are made of alloyed steels with hardnesses between 50 and 70 HRC [1]. The main aim of employing hard turning is avoiding the grinding operation which in most cases corresponds to the final operation for the workpiece. Comparisons between both processes show that the demanded surface roughness and ISO tolerance standards can be achieved in both processes, but higher flexibility and material removal rates can be obtained in hard turning.

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Modeling of White and Dark Layer Formation in Hard Machining of Aisi 52100 Bearing Steel

Cited by 58 publications

References 10 publications

Evaluation of different approaches for modeling phase transformations in machining simulation

Evaluation of different approaches for modeling phase transformations in machining simulation

Material microstructure affected machining: a review

Finite-element Modeling and Simulation

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