On adiabatic shear localized fracture during serrated chip evolution in high speed machining of hardened AISI 1045 steel

2013 ◽  
Vol 75 ◽  
pp. 288-298 ◽  
Author(s):  
Gu Liyao ◽  
Wang Minjie ◽  
Duan Chunzheng
Keyword(s):  
High Speed ◽  
Adiabatic Shear ◽  
High Speed Machining ◽  
Serrated Chip ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Microscopic Observation of White Band within Shear Zone of Chip Produced during High Speed Machining of AISI 1045 Hardness Steel

2011 ◽  
Vol 474-476 ◽  
pp. 1292-1295
Author(s):  
Chun Zheng Duan ◽  
Wei Sen Kong ◽  
Zhao Xi Wang ◽  
Min Jie Wang
Keyword(s):  
Deformation Zone ◽  
High Speed ◽  
Chemical Elements ◽  
Adiabatic Shear ◽  
High Speed Machining ◽  
X Ray Diffraction ◽  
Serrated Chip ◽  
White Band ◽  
Aisi 1045 ◽  
Serrated Chips

To study the microstructure of white band is helpful for revealing formation mechanism of serrated chip. This paper investigates the microstructural characteristics of white bandsat primary and second deformation zone within the serrated chips produced during High Speed Machining (HSM) of AISI 1045 hardened steel usingoptical microscope, SEM, TEM, and electron microprobe, X-Ray diffraction. It was found that the white bands within primary and second deformation zone consist of small equiaxed grains which formed due to dynamic recrystallization during adiabatic shear, however, martensitic transformation just only taken place within the white band in second deformation zone. The re-distribution of chemical elements between the composition phases occurred due to the combined effect of adiabatic temperature rise and high speed deformation in formation process of white band. The former is result from adiabatic shear in primary deformation zone during formation of chip, while the latter is caused by the intense shear and friction between tool and chip.

Effect on Flow Stress of a Rapid Phase Transition in AISI 1045 Steel

2011 ◽  
Author(s):  
Timothy J. Burns ◽  
Steven P. Mates ◽  
Richard L. Rhorer ◽  
Eric P. Whitenton ◽  
Debasis Basak
Keyword(s):  
Phase Transition ◽  
High Speed ◽  
Compressive Loading ◽  
Kolsky Bar ◽  
High Speed Machining ◽  
Eutectoid Temperature ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Cook Model

New experimental data on AISI 1045 steel from the NIST pulse-heated Kolsky Bar Laboratory are presented. The material is shown to exhibit a nonequilibrium phase transformation at high strain rate. An interesting feature of these data is that the material has a stiffer response to compressive loading when it has been preheated to a testing temperature that is below the eutectoid temperature using pulse-heating than it does when it has been preheated using a slower heating method. On the other hand, when the material has been pulse-heated to a temperature that exceeds the eutectoid temperature prior to compressive loading on the Kolsky bar, it is shown to exhibit a significant loss of strength. A consequence of this behavior is that fixed-parameter constitutive models, such as the well-known Johnson-Cook model, cannot be used to describe this constitutive response behavior. An argument is made that the phase transition does not occur during high-speed machining operations, and suggestions are made as to how to modify the Johnson-Cook model of Jaspers and Dauzenberg for this material in order to obtain improved temperature predictions in finite-element simulations of high-speed machining processes.

Investigation of the Effects of Microgrooved Cutting Tool in High Speed Machining of AISI 1045 Steel

2017 ◽  
Author(s):  
Xingbang Chen ◽  
Nick H. Duong ◽  
J. Ma ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Contact Length ◽  
High Speed Machining ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Cutting Inserts ◽  
1045 Steel

In this paper, numerical investigation of the effects of microgroove textured cutting tools in high speed machining of AISI 1045 is conducted using Finite Element Method (FEM). Microgrooves are designed and fabricated on the rake face of cemented carbide (WC/Co) cutting inserts. The effects of microgroove width, edge distance (the distance from cutting edge to the first microgroove), and microgroove depth are examined and assessed in terms of main cutting force, thrust force, and tool-chip contact length. It is found that microgrooved cutting tools generate lower cutting force and consequently lower the energy necessary for machining. This research provides insightful guidance for optimizing tool life and reducing energy consumption in high-speed machining of AISI 1045 steel.

CEL FEM Investigation of Effects of Microgrooved Cutting Tools in High Speed Machining of AISI 1045 Steel

2017 ◽  
Author(s):  
Han Wu ◽  
Nick H. Duong ◽  
J. Ma ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
High Speed Machining ◽  
Rake Face ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

In this paper, the commercial FEM software package Abaqus is used to investigate the effects of microgrooved cutting tools in high speed orthogonal cutting of AISI 1045 steel. Microgrooves are designed and fabricated on the rake face of cemented carbide (WC/Co) cutting inserts. A coupled Eulerian-Lagrangian (CEL) finite element model is developed based on Abaqus to solve the evolution of the cutting temperature, chip morphology, cutting force, and phase constitutes simultaneously. This model is validated by comparing the numerical results with the experimental data for orthogonal high speed cutting of AISI 1045 steel with various cutting conditions. In addition, this model is also validated by comparing with the experimental data of regular tool and microgrooved cutting tool under the cutting speed of 120m/min. This validated CEL FEM model is then utilized to investigate the effects of microgrooved cutting tools on the phase transformation, cutting force, cutting temperature, and chip morphology in high speed orthogonal cutting of AISI 1045. The effects of microgroove width, edge distance (the distance from cutting edge to the first microgroove), and microgroove depth are examined and assessed in terms of cutting force, cutting temperature, chip morphology, and phase transformation. It is found that this CEL FEM model can capture the essential features of orthogonal high speed cutting of AISI 1045 using microgrooved cutting tools. It is also concluded that microgrooved cutting tools can not effectively reduce the cutting force in high speed machining, which is contrary to the conclusion obtained for low speed machining in previous research. However, microgrooves on the rake face have influence on the austenite percentage in the chip near the rake face. This research provides insightful guidance for optimizing the cutting performance in terms of cutting temperature, cutting force, chip morphology, and phase transformation in high speed machining of AISI 1045 steel.

Prediction of Critical Cutting Conditions of Adiabatic Shear in Orthogonal High Speed Cutting Based on Linear Pertubation Analysis

2010 ◽  
Vol 455 ◽  
pp. 137-140 ◽  
Author(s):  
Guo He Li ◽  
Min Jie Wang ◽  
Yu Jun Cai
Keyword(s):  
High Speed ◽  
Adiabatic Shear ◽  
Cutting Conditions ◽  
Critical Conditions ◽  
Linear Perturbation ◽  
High Speed Cutting ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Basic Equations ◽  
1045 Steel

A model is presented for the prediction of critical cutting conditions of adiabatic shear in orthogonal high speed cutting. Considering the influence of compression stress, a critical criterion of adiabatic shear in orthogonal high speed cutting is given by linear perturbation on the compress-shear deformation continuum mechanics basic equations of the primary shear zone. Combining with the relationship of cutting conditions and deformation ones, also the materials constitutive realtionship, a pridiction model, which expressed by cutting conditions and materials properties is established. As an example, the adiabatic shear critical conditions of AISI 1045 steel are predicted, and cutting experiments are performed. The prediction results are consistent with that of experiments.

Prediction of the Surface Roughness in High-Speed Machining Based on Molecular-Mechanical Theory of Friction

2011 ◽  
Vol 308-310 ◽  
pp. 1134-1138 ◽  
Author(s):  
Su Yu Wang ◽  
Wen Chao Wang ◽  
Tao Yu ◽  
Bin Jiang
Keyword(s):  
Surface Roughness ◽  
Flow Stress ◽  
Mechanical Model ◽  
High Speed ◽  
High Speed Machining ◽  
Mechanical Theory ◽  
Machined Surface ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Surface roughness is an important parameter to evaluate the quality of high-speed machining (HSM). This paper establishes a mechanical model based on the molecular-mechanical theory of friction to study factors that influence the surface roughness in HSM. The relationship between flow stress and the remnant height on the machined surface is obtained. The HSM process of AISI-1045 steel is simulated by using finite element method (FEM) based on DEFORM-2D and the flow stress is obtained. The surface roughness of workpiece machined by HSM is calculated based on the value of flow stress and the mechanical model. The result shows that the surface roughness of workpiece in HSM is acceptable, and the mechanical model supplies a method to study the surface roughness in HSM.

Prediction of Adiabatic Shear Critical Cutting Conditions of hardened AISI 1045 Steel with Different Hardness

2013 ◽  
Vol 589-590 ◽  
pp. 134-139
Author(s):  
Guo He Li ◽  
Yu Jun Cai ◽  
Hou Jun Qi
Keyword(s):  
Model Building ◽  
Orthogonal Cutting ◽  
Adiabatic Shear ◽  
Cutting Conditions ◽  
Constitutive Relationship ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Relationship Of ◽  
1045 Steel ◽  
Cutting Experiments

A method for building the constitutive relationship based on the J-C model and hardness is presented through considering the influence of hardness on the yield strength and the tensile strength. A constitutive relationship of hardened AISI 1045 is built by this method and the adiabatic shear critical cutting conditions of three kinds of hardness AISI 1045 steel are prediction through a model building by the linear pertubation analysis which considering the influence of compression stress of the primary shear zone, the cutting conditions and the constitutive relationship. For proving the prediction results, some orthogonal cutting experiments are performed to get the critical cutting conditions of adiabatic shear. The comparison shows that the prediction results are consistent with that of experiments.

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