scholarly journals Plastic Deformation and Residual Stress in High Speed Turning of AD730™ Nickel-based Superalloy with PCBN and WC Tools

Procedia CIRP ◽  
2018 ◽  
Vol 71 ◽  
pp. 440-445 ◽  
Author(s):  
Z Chen ◽  
J.M. Zhou ◽  
R.L. Peng ◽  
R M’Saoubi ◽  
D Gustafsson ◽  
...  
Keyword(s):  
Residual Stress ◽  
Plastic Deformation ◽  
High Speed ◽  
High Speed Turning ◽  
Nickel Based Superalloy

Residual Stresses in High Speed Turning of Nickel-Based Superalloy*

2014 ◽  
Vol 69 (1) ◽  
pp. 46-53 ◽  
Author(s):  
R. L. Peng ◽  
J.-M. Zhou ◽  
S. Johansson ◽  
A. Bellinius ◽  
V. Bushlya ◽  
...  
Keyword(s):  
Residual Stresses ◽  
High Speed ◽  
High Speed Turning ◽  
Nickel Based Superalloy

scholarly journals Residual Stresses in High Speed Turning of Thin-Walled Cylindrical Workpieces

2011 ◽  
Vol 5 (3) ◽  
pp. 313-319 ◽  
Author(s):  
Ekkard Brinksmeier ◽  
◽  
Carsten Heinzel ◽  
Martin Garbrecht ◽  
Jens Sölter ◽  
...  
Keyword(s):  
Residual Stress ◽  
High Speed ◽  
Cutting Speed ◽  
Basic Research ◽  
Shape Deviation ◽  
High Speed Turning ◽  
Aisi 52100 ◽  
Functional Part ◽  
Thin Walled ◽  
Cutting Processes

Residual stress induced in cutting processes substantially impacts adversely on functional part performance and distortion, especially when thin-walled workpieces are machined. For this reason, basic research focuses on the correlation between a specific high-speed turning configuration and the occurrence of residual stress and the amount of resulting distortion. The presented experiments in high-speed turning of thin-walled AISI 52100 (100Cr6) steel workpieces show, that residual stress distribution in the surface layer moves toward compressive stress as cutting speed increases while feed and lower wall-thickness decrease. Indications were also, that increasing cutting speed leads to higher distortion. To evaluate residual stress potential in shape deviation, the so-called source forceF’sourcewas calculated by numerically integrating the residual stress depth profile.

Experimental Study of Green High-Speed Turning Nickel-Based Superalloy GH4169

2010 ◽  
Vol 26-28 ◽  
pp. 1132-1136
Author(s):  
Jun Zhou ◽  
Rong Di Han
Keyword(s):  
Water Vapor ◽  
High Speed ◽  
Cutting Temperature ◽  
Operating Conditions ◽  
Dry Cutting ◽  
Machined Surface ◽  
High Speed Turning ◽  
Nickel Based Superalloy ◽  
Cooling Lubricant ◽  
Lubricant Application

Knowing the stringent operating conditions to which superalloys are subjected to in automobile, aerospace and gas turbine industries, the machinability of nickel-based superalloy GH4169 is very poor, the traditional cutting fluids in GH4169 machining pollutes environments. The purpose of this study is to clarify the possibility of the turning in high speed (vc＞50m/min)[1]. In particular, the effects of the overheat water vapor with 130°C as cooling lubricant application were examined, through observation and measurement of the shape of the generated chips, machined surface integrity, cutting force and cutting temperature in a series of experiments with dry cutting or overheat water vapor with 130°C as cooling lubricant. As a result of these experiments, it was possible to measure and confirm the effects of the overheat water vapor with 130°C as cooling lubricant in high speed turning.

Simulation and Experiment on the Residual Stress in Super-High Speed Grinding

2010 ◽  
Vol 135 ◽  
pp. 238-242
Author(s):  
Yue Ming Liu ◽  
Ya Dong Gong ◽  
Wei Ding ◽  
Ting Chao Han
Keyword(s):  
Residual Stress ◽  
High Speed ◽  
Element Model ◽  
Residual Stress Distribution ◽  
X Ray Diffraction ◽  
Machined Surface ◽  
X Ray ◽  
High Speed Grinding ◽  
Simulation And Experiment ◽  
Cylindrical Workpiece

In this paper, effective finite element model have been developed to simulation the plastic deformation cutting in the process for a single particle via the software of ABAQUS, observing the residual stress distribution in the machined surface, the experiment of grinding cylindrical workpiece has been brought in the test of super-high speed grinding, researching the residual stress under the machined surface by the method of X-ray diffraction, which can explore the different stresses from different super-high speed in actual, and help to analyze the means of reducing the residual stresses in theory.

scholarly journals The Performance of Polycrystalline Diamond (PCD) Tools Machined by Abrasive Grinding and Electrical Discharge Grinding (EDG) in High-Speed Turning

2021 ◽  
Vol 5 (2) ◽  
pp. 34
Author(s):  
Guangxian Li ◽  
Ge Wu ◽  
Wencheng Pan ◽  
Rizwan Abdul Rahman Rashid ◽  
Suresh Palanisamy ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Flank Wear ◽  
Polycrystalline Diamond ◽  
Machining Efficiency ◽  
Crater Wear ◽  
Wear Process ◽  
High Speed Turning ◽  
Tools Wear ◽  
Pcd Tools

Polycrystalline diamond (PCD) tools are widely used in industry due to their outstanding physical properties. However, the ultra-high hardness of PCD significantly limits the machining efficiency of conventional abrasive grinding processes, which are utilized to manufacture PCD tools. In contrast, electrical discharge grinding (EDG) has significantly higher machining efficiency because of its unique material removal mechanism. In this study, the quality and performance of PCD tools machined by abrasive grinding and EDG were investigated. The performance of cutting tools consisted of different PCD materials was tested by high-speed turning of titanium alloy Ti6Al4V. Flank wear and crater wear were investigated by analyzing the worn profile, micro morphology, chemical decomposition, and cutting forces. The results showed that an adhesive-abrasive process dominated the processes of flank wear and crater wear. Tool material loss in the wear process was caused by the development of thermal cracks. The development of PCD tools’ wear made of small-sized diamond grains was a steady adhesion-abrasion process without any catastrophic damage. In contrast, a large-scale fracture happened in the wear process of PCD tools made of large-sized diamond grains. Adhesive wear was more severe on the PCD tools machined by EDG.

scholarly journals Verification of electric steel punching simulation results using microhardness

2021 ◽  
Author(s):  
Sampsa Vili Antero Laakso ◽  
Ugur Aydin ◽  
Peter Krajnik
Keyword(s):  
Plastic Deformation ◽  
High Speed ◽  
Steel Sheet ◽  
Electrical Steel ◽  
High Speed Steel ◽  
Experimental Methods ◽  
Fem Simulations ◽  
Iron Losses ◽  
Simulation Results ◽  
Electrical Steel Sheet

AbstractOne of the most dominant manufacturing methods in the production of electromechanical devices from sheet metal is punching. In punching, the material undergoes plastic deformation and finally fracture. Punching of an electrical steel sheet causes plastic deformation on the edges of the part, which affects the magnetic properties of the material, i.e., increases iron losses in the material, which in turn has a negative effect on the performance of the electromagnetic devices in the final product. Therefore, punching-induced iron losses decrease the energy efficiency of the device. FEM simulations of punching have shown significantly increased plastic deformation on the workpiece edges with increasing tool wear. In order to identify the critical tool wear, after which the iron losses have increased beyond acceptable limits, the simulation results must be verified with experimental methods. The acceptable limits are pushed further in the standards by the International Electrotechnical Commission (IEC). The new standard (IEC TS 60034-30-2:2016) has much stricter limits regarding the energy efficiency of electromechanical machines, with an IE5 class efficiency that exceeds the previous IE4 class (IEC 60034-30-1:2014) requirements by 30%. The simulations are done using Scientific Forming Technologies Corporation Deform, a finite element software for material processing simulations. The electrical steel used is M400-50A, and the tool material is Vanadis 23, a powder-based high-speed steel. Vanadis 23 is a high alloyed powder metallurgical high-speed steel with a high abrasive wear resistance and a high compressive strength. It is suitable for cold work processing like punching. In the existing literature, FEM simulations and experimental methods have been incorporated for investigating the edge deformation properties of sheared surfaces, but there is a research gap in verifying the simulation results with the experimental methods. In this paper, FEM simulation of the punching process is verified using an electrical steel sheet from real production environment and measuring the deformation of the edges using microhardness measurements. The simulations show high plastic deformation 50 μm into the workpiece edge, a result that is shown to be in good agreement with the experimental results.

Effect of Residual Stress or Plastic Deformation History on Fatigue Life Simulation of Pipeline Dents

2018 ◽  
Author(s):  
Xian-Kui Zhu ◽  
Rick Wang
Keyword(s):  
Residual Stress ◽  
Plastic Deformation ◽  
Fatigue Life ◽  
Residual Stresses ◽  
Three Dimensional ◽  
Strain History ◽  
Deformation History ◽  
Stress Strain ◽  
Element Analysis ◽  
Fea Model

Mechanical dents often occur in transmission pipelines, and are recognized as one of major threats to pipeline integrity because of the potential fatigue failure due to cyclic pressures. With matured in-line-inspection (ILI) technology, mechanical dents can be identified from the ILI runs. Based on ILI measured dent profiles, finite element analysis (FEA) is commonly used to simulate stresses and strains in a dent, and to predict fatigue life of the dented pipeline. However, the dent profile defined by ILI data is a purely geometric shape without residual stresses nor plastic deformation history, and is different from its actual dent that contains residual stresses/strains due to dent creation and re-rounding. As a result, the FEA results of an ILI dent may not represent those of the actual dent, and may lead to inaccurate or incorrect results. To investigate the effect of residual stress or plastic deformation history on mechanics responses and fatigue life of an actual dent, three dent models are considered in this paper: (a) a true dent with residual stresses and dent formation history, (b) a purely geometric dent having the true dent profile with all stress/strain history removed from it, and (c) a purely geometric dent having an ILI defined dent profile with all stress/strain history removed from it. Using a three-dimensional FEA model, those three dents are simulated in the elastic-plastic conditions. The FEA results showed that the two geometric dents determine significantly different stresses and strains in comparison to those in the true dent, and overpredict the fatigue life or burst pressure of the true dent. On this basis, suggestions are made on how to use the ILI data to predict the dent fatigue life.

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