The Effect of Microstructure on Chip Formation and Surface Defects in Microscale, Mesoscale, and Macroscale Cutting of Steel

Simoneau, A.; Ng, E. G.; Elbestawi, M.A.

doi:10.1016/s0007-8506(07)60375-8

Cited by 39 publications

(14 citation statements)

References 9 publications

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“…In this type of simulation, elements having reached a critical value of accumulated damage are subsequently removed from the analysis. Recently, this technique has been successfully applied to simulate the formation of serrated or segmented chips, such as when machining a heterogeneous material [31] or when using a negative rake angle. [32] Another direction for finite element development, more pertinent to the model presented in this study, involves Lagrangian mesh formulation with iterative remeshing.…”

Section: A Previous Modelsmentioning

confidence: 99%

Severe Plastic Deformation by Machining Characterized by Finite Element Simulation

Sevier

Yang

Lee

et al. 2007

Metall Mater Trans B

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A finite element model of large strain deformation in machining is presented in the context of using machining as a controlled method for severe plastic deformation (SPD). Various characteristics of the large strain deformation field associated with chip formation, including strain, strain distribution, strain rate, and velocity field, are calculated using the model and compared with direct measurements in plane strain machining. Reasonable agreement is found for all cases considered. The versatility and accuracy of the finite element model are demonstrated, especially in the range of highly negative rake angles, wherein the shear plane model of machining is less applicable due to the nature of material flow around the tool cutting edge. The influence of the tool rake angle and friction at the tool-chip interface on the deformation is explored and used to establish correspondences between controllable machining input parameters and deformation parameters. These correspondences indicate that machining is a viable, controlled method of severe plastic deformation. Implications of the results for creation of nanostructured and ultrafine-grained alloys by machining are briefly highlighted.

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Section: A Previous Modelsmentioning

confidence: 99%

Severe Plastic Deformation by Machining Characterized by Finite Element Simulation

Sevier

Yang

Lee

et al. 2007

Metall Mater Trans B

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“…It was reported that microburrs, one of the cornmon defects in microcutting of multiphase materials, account for 20-^0% of the total surface roughness [6]. In addition, the presence of other defects such as dimples, prows, rnicrovoids, and microcracks after machining steel was investigated irrespective of the cutting conditions [12][13][14][15][16][17]. It was reported that these defects should be attributed to the presence of a second phase in the material microstructure.…”

Section: Introductionmentioning

confidence: 99%

“…The results revealed that by refining the material microstructure, the negative scale effects of reducing the chip thickness could be minimized. The authors then used findings of this research to develop a new heterogeneous finite element model to simulate the behavior of multipha.se materials [15][16][17].…”

Section: Introductionmentioning

confidence: 99%

“…Most of the research reported was experimental in its nature, and only some attempts were made to model the effects of material microstructure in micromilling employing a finite element analysis (FEA) [6,8,[13][14][15][16][17]. However, such simulation models were used mostly to understand better the mechanics of the microcutting process, and not as a tool for process optimization [15].…”

Section: Introductionmentioning

confidence: 99%

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Modeling the Material Microstructure Effects on the Surface Generation Process in Microendmilling of Dual-Phase Materials

Elkaseer

Dimov

Popov³

et al. 2012

Journal of Manufacturing Science and Engineering

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The anisotropic behavior of the material microstructure when processing multiphase materials at microscale becomes an important factor that has to be considered throughout the machining process. This is especially the case when chip-loads and machined features are comparable in size to the cutting edge radius of the tool, and also similar in scale to the grain sizes of the phases present within the material microstructure. Therefore, there is a real need for reliable models, which can be used to simulate the surface generation process during microendmilling of multiphase mate rials.This paper presents a model to simulate the surface generation process during microendmilling of multiphase materials. The proposed model considers the effects of the following factors; the geometry of the cutting tool, the feed rate, and the workpiece material microstructure. Especially, variations of the minimum chip thickness at phase boundaries are considered by feeding maps of the material microstructure into the model. Thus, the model takes into account these variations that alter the machining mechanism from a proper cut-. Assoc. Editor: Komel Ehmann. ting to ploughing and vice versa, and are the main cause of microburr formation. By applying the proposed model, it is possible to estimate more accurately the resulting roughness because the microburr formation dominates the swface generation process during microendmilling of multiphase materials. The proposed model was experimentally validated by machining two different samples of dual-phase steel under a range of chip-loads. The roughness of the resulting swfaces was measured and compared to the predictions of the proposed model under the same cutting conditions. The results show that the proposed model accurately predicts the roughness of the machined surfaces by taking into account the effects of material multiphase microstructure. Also, the developed model successfully elucidates the mechanism of microburr formation at the phase boundaries, and quantitatively describes its contributions to the resulting swface roughness after microendmilling.

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“…Por outro lado, os modelos citados acima são úteis para se obter valiosas informações, como, por exemplo, que o ângulo de saída maior implica em forças menores e que o atrito entre cavaco e ferramenta deve ser diminuído ao máximo. A microestrutura do material foi abordada por Liang et al (1994) em uma pesquisa sobre os efeitos da anisotropia e dos contornos de grãos em usinagem e por Simoneau et al (2006aSimoneau et al ( , 2006bSimoneau et al ( , 2007aSimoneau et al ( , 2007b Importantes contribuições para o desenvolvimento de modelos mais precisos vieram do estudo do atrito da interface cavaco-ferramenta, pesquisados por Arrazola et al (2008), Haglund et al (2008), Valiorgue et al (2008), Özel (2006) e Özel e Altan (2000) e de experimentos realizados por Grzesik (1999Grzesik ( , 2000. Muitos outros trabalhos na área relacionados à usinagem e ao MEF podem ser encontrados nos trabalhos de Mackerle (1999Mackerle ( , 2003.…”

Section: Modelos Mecanísticosunclassified

Estudo teórico-experimental das forças de corte no processo de torneamento

Cervelin¹

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The Effect of Microstructure on Chip Formation and Surface Defects in Microscale, Mesoscale, and Macroscale Cutting of Steel

Cited by 39 publications

References 9 publications

Severe Plastic Deformation by Machining Characterized by Finite Element Simulation

Severe Plastic Deformation by Machining Characterized by Finite Element Simulation

Modeling the Material Microstructure Effects on the Surface Generation Process in Microendmilling of Dual-Phase Materials

Estudo teórico-experimental das forças de corte no processo de torneamento

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