White layer formation mechanism in dry turning hardened steel

Duan, Chunzheng; Zhang, Fangyuan; Sun, Wei; Xu, Xinxin; Wang, Minjie

doi:10.1299/jamdsm.2018jamdsm0044

Cited by 10 publications

(5 citation statements)

References 30 publications

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“…X-ray phase analysis conducted on machined samples showed that the peaks had a lower relative intensity compared to the as-received samples. The same pattern had also been obtained by other researchers [9,43]. Figure 7 shows the X-ray spectra of the samples before and after machining at the various planes of (110), (101), and (200).…”

Section: Resultssupporting

confidence: 79%

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Cryogenic milling and formation of nanostructured machined surface of AISI 4340

Muhamad

Ghani

Haron

et al. 2020

Nanotechnology Reviews

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Hardened layers are commonly required for automotive components after their production using a machining process in order to enhance the service life of these components. This study investigates the possibility of producing a nanostructured machined surface which can increase the hardness of the machined surface by varying the machining parameters under cryogenic conditions in end milling of AISI 4340. The end milling experiments were performed using multi-layered TiAlN- and AlCrN-coated carbide. Prior to the experiment, a finite element method (FEM) was used to simulate the cutting temperature generated and it had been found that at cutting speed of 200–300 m/min, feed rate of 0.15–0.3 mm/tooth, axial depth of cut of 0.3–0.5 mm, and radial depth of cut of 0.2–0.35 mm, the temperature generated can be sufficiently high to cause austenitic transformation. A field emission scanning electron microscope (FESEM) equipped with angle selective backscattered (AsB) detection analysis was used to investigate the microstructure and machined-affected layers of the machined surfaces. The crystallographic orientation/phase change and nano-hardness were analysed through X-ray diffraction (XRD) and a nano-hardness testing machine. The results showed that the cryogenic machining had significantly affected the surface integrity characteristics of the AISI 4340 alloy due to refined microstructure, favourable phase structure, and higher hardness near the surface layer. The results of this study may be useful in providing an insight into a potential technological shift from conventional surface case hardening processes to the present technique.

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Section: Resultssupporting

confidence: 79%

“…The results of this investigation show that the machineaffected layer is induced by the interaction of phase transformation and plastic deformation. The fine crystal sizes and high strains are due to plastic deformation which occurs during machining, as reported by Duan et al [43].…”

Section: Resultsmentioning

confidence: 58%

Cryogenic milling and formation of nanostructured machined surface of AISI 4340

Muhamad

Ghani

Haron

et al. 2020

Nanotechnology Reviews

View full text Add to dashboard Cite

show abstract

“…Zhang et al [44] also observed that the thickness of the white layer decreased with an increase in cutting speed. Therefore, the formation of the white layer cannot be fully explained by the "thermal-strain rate mechanism" alone [45][46][47]. The critical temperature for the formation of a white layer decreases with an increase in strain but a decrease in strain rate [48].…”

Section: Formation Mechanisms Of Machining Metamorphic Layermentioning

confidence: 99%

Surface Integrity of Inconel 738LC Parts Manufactured by Selective Laser Melting Followed by High-speed Milling

Ren

Guo

Zhang

2023

Chin. J. Mech. Eng.

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This study is concerned with the surface integrity of Inconel 738LC parts manufactured by selective laser melting (SLM) followed by high-speed milling (HSM). In the investigation process of surface integrity, the study employs ultra-depth three-dimensional microscopy, laser scanning confocal microscopy, scanning electron microscopy, electron backscatter diffractometry, and energy dispersive spectroscopy to characterize the evolution of material microstructure, work hardening, residual stress coupling, and anisotropic effect of the building direction on surface integrity of the samples. The results show that SLM/HSM hybrid manufacturing can be an effective method to obtain better surface quality with a thinner machining metamorphic layer. High-speed machining is adopted to reduce cutting force and suppress machining heat, which is an effective way to produce better surface mechanical properties during the SLM/HSM hybrid manufacturing process. In general, high-speed milling of the SLM-built Inconel 738LC samples offers better surface integrity, compared to simplex additive manufacturing or casting.

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“…Meanwhile, the austenite transition of the white layer is enhanced by plastic deformation. Duan et al [14] studied the white-layer formation mechanism through the experiments of orthogonal turning AISI52100 and AISI4340 steels. The results indicated that the white layer was generated due to the coupling effects of phase transition and plastic deformation.…”

Section: Introductionmentioning

confidence: 99%

A Multiphysics Model for Predicting Microstructure Changes and Microhardness of Machined AerMet100 Steel

et al. 2022

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The machined-surface integrity plays a critical role in corrosion resistance and fatigue properties of ultra-high-strength steels. This work develops a multiphysics model for predicting the microstructure changes and microhardness of machined AerMet100 steel. The variations of stress, strain and temperature of the machined workpiece are evaluated by constructing a finite-element model of the orthogonal cutting process. Based on the multiphysics fields, the analytical models of phase transformation and dislocation density evolution are built up. The white layer is modeled according to the phase-transformation mechanism and the effects of stress and plastic strain on real phase-transformation temperature are taken into consideration. The microhardness changes are predicted by a model that accounts for both dislocation density and phase-transformation evolution processes. Experimental tests are carried out for model validation. The predicted results of cutting force, white-layer thickness and microhardness are in good agreement with the measured data. Additionally, from the proposed model, the correlation between the machined-surface characteristics and processing parameters is established.

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White layer formation mechanism in dry turning hardened steel

Cited by 10 publications

References 30 publications

Cryogenic milling and formation of nanostructured machined surface of AISI 4340

Cryogenic milling and formation of nanostructured machined surface of AISI 4340

Surface Integrity of Inconel 738LC Parts Manufactured by Selective Laser Melting Followed by High-speed Milling

A Multiphysics Model for Predicting Microstructure Changes and Microhardness of Machined AerMet100 Steel

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