Turning Force Prediction of AISI 4130 Considering Dynamic Recrystallization

Thermal mechanical loadings in machining process would promote material microstructure changes. The material microstructure evolution, such as grain size evolution and phase transformation could significantly influence the material flow stress behavior, which will directly affect the machining forces. An analytical model is proposed to predict cutting forces during the turning of AISI 4130 steel. The material dynamic recrystallization is considered through Johnson-Mehl-Avrami-Kolmogorov (JMAK) model. The explicit calculation of average grain size is provided in an analytical model. The grain size effect on the material flow stress is considered by introducing the Hall-Petch relation into a modified Johnson-Cook model. The cutting forces prediction are based on Oxley’s contact mechanics with consideration of mechanical and thermal loads. The model is validated by comparing the predicted machining forces with experimental measurements.

Download Full-text

Analytical and Numerical Predictions of Machining-Induced Residual Stress in Milling of Inconel 718 Considering Dynamic Recrystallization

Volume 4: Processes ◽

10.1115/msec2018-6386 ◽

2018 ◽

Cited By ~ 2

Author(s):

Yixuan Feng ◽

Zhipeng Pan ◽

Xiaohong Lu ◽

Steven Y. Liang

Keyword(s):

Residual Stress ◽

Grain Size ◽

Flow Stress ◽

Dynamic Recrystallization ◽

Analytical Model ◽

Inconel 718 ◽

Milling Process ◽

Stress Profile ◽

Recrystallization Process ◽

Numerical Predictions

A new analytical model is proposed to predict the residual stress in the milling process of Inconel 718 based upon the mechanics analysis of microstructural evolutions. The model proposes to quantify the effects of dynamic recrystallization process on the material flow stress under combined thermal-mechanical loadings in machining. Physics-based mechanistic model is applied to predict the percentage of dynamic recrystallization and the grain size as functions of the milling process parameters and materials constative attributes. The variation of grain size is expected to alter the yield stress, and such dependency relationship is applied to predict the flow stress, which is also dependent on strain, strain rate, and temperature. The time-varying trajectory of residual stress is then predicted at each milling rotation angle through the transformation from milling to equivalent orthogonal cutting, the calculation of stress distribution in loading process, and the stress change during relaxation. The results of analytical model are validated through numerical prediction. The residual stress profile predicted by proposed analytical model matches better with results from numerical model comparing with model without consideration of dynamic recrystallization, especially within subsurface area, with improved accuracy of peak compressive residual stress prediction.

Download Full-text

The Effect of Material Flow Stress on Analytical Simulation of Machining

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.29-32.1809 ◽

2010 ◽

Vol 29-32 ◽

pp. 1809-1814

Author(s):

Bing Lin Li ◽

Ling Ling ◽

Yu Jin Hu ◽

Xue Lin Wang

Keyword(s):

Flow Stress ◽

Shear Zone ◽

Analytical Model ◽

Material Flow ◽

Model Simulation ◽

Orthogonal Cutting ◽

Shear Plane ◽

Thermomechanical Model ◽

Workpiece Material ◽

Flow Stress Data

The flow stress data of the workpiece are extremely crucial for the cutting simulation. The study shows how the input data affect the analytical predictions of cutting force and temperature. The Johnson-Cook material model is used to represent workpiece flow stress in the primary shear zone. A thermomechanical model of orthogonal cutting is proposed based on the main shear plane divides the primary shear zone into two unequal parts. Five different sets of workpiece material flow stress data used in the Johnson-Cook’s constitutive equation are chosen and make the sensitivity analysis for analytical model. Simulation results were compared to orthogonal cutting test data from the available literature, and find the effects of flow stress on analytical model was different from that for finite element model.

Download Full-text

Flow Stress Behavior of Nanometric Al2O3 Particulate Reinforced Al Alloy Composites Manufactured by Casting

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.430-432.1294 ◽

2012 ◽

Vol 430-432 ◽

pp. 1294-1297

Author(s):

Zhi Min Zhang ◽

Yong Biao Yang ◽

Xing Zhang

Keyword(s):

Grain Size ◽

Flow Stress ◽

Dynamic Recrystallization ◽

Al Alloy ◽

Strain Rates ◽

Stress Behavior ◽

Flow Stress Behavior ◽

Increasing Temperature ◽

Particulate Reinforced ◽

Temperature Dynamic

The flow stress behavior of nanometric Al2O3 particulate reinforced Al alloy composites were investigated using thermal simulation machine Gleeble-1500. Microsturctural analysis were carried out on optical microscopy. The results showed that the flow stress increased with increasing strain rate and decreased with decreasing temperature. Dynamic recovery and dynamic recrystallization occurred during hot compression of the Al composites. The grain size increased with increasing temperature (590k-710k) and decreased at 750k due to dynamic recrystallization. The grain size decreased with increasing strain rates at 750k.

Download Full-text

Predicting Cutting Forces for Oblique Machining Conditions

Proceedings of the Institution of Mechanical Engineers ◽

10.1243/pime_proc_1982_196_015_02 ◽

1982 ◽

Vol 196 (1) ◽

pp. 141-148 ◽

Cited By ~ 33

Author(s):

G C I Lin ◽

P Mathew ◽

P L B Oxley ◽

A R Watson

Keyword(s):

Thermal Properties ◽

Flow Stress ◽

Cutting Force ◽

Plane Strain ◽

Cutting Forces ◽

Material Flow ◽

Cutting Conditions ◽

Orthogonal Plane ◽

Simplifying Assumptions ◽

Experimental Cutting

Using orthogonal (plane strain) machining theory together with certain simplifying assumptions based on experimental observations it is shown how the three components of cutting force in oblique machining can be predicted from a knowledge of the work material flow stress and thermal properties and the cutting conditions. A comparison of predicted and experimental cutting force results is given.

Download Full-text

The Influence of Static and Dynamic Recrystallization on Mean Flow Stress and Grain Size in Steel

Canadian Metallurgical Quarterly ◽

10.1179/cmq.1994.33.2.145 ◽

1994 ◽

Vol 33 (2) ◽

pp. 145-154 ◽

Cited By ~ 4

Author(s):

S. Yue ◽

D. Q. Bai ◽

J. J. Jonas

Keyword(s):

Grain Size ◽

Flow Stress ◽

Dynamic Recrystallization ◽

Mean Flow ◽

Mean Flow Stress

Download Full-text

A mean field model of dynamic and post-dynamic recrystallization predicting kinetics, grain size and flow stress

Computational Materials Science ◽

10.1016/j.commatsci.2015.02.043 ◽

2015 ◽

Vol 102 ◽

pp. 293-303 ◽

Cited By ~ 30

Author(s):

O. Beltran ◽

K. Huang ◽

R.E. Logé

Keyword(s):

Grain Size ◽

Flow Stress ◽

Dynamic Recrystallization ◽

Field Model ◽

Mean Field ◽

Mean Field Model

Download Full-text

Compressing Deformation and Microstructure of AZ61 Magnesium Alloy

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1015.203 ◽

2014 ◽

Vol 1015 ◽

pp. 203-206

Author(s):

Quan Li ◽

Jin Yang ◽

Wen Jun Liu ◽

Su Qin Luo ◽

Ren Ju Cheng ◽

...

Keyword(s):

Grain Size ◽

Flow Stress ◽

Magnesium Alloy ◽

Dynamic Recrystallization ◽

Strain Rate ◽

Deformation Temperature ◽

Hot Compression ◽

Compression Tests ◽

Az61 Magnesium Alloy

Hot compression tests of AZ61 magnesium alloy were performed on gleeble1500D at strain rate ranged in 0.01~1s-1 and deformation temperature 350~400°C.The results show that the flow stress and microstructures strongly depend on the deformation temperature and the strain rate. When the temperature was reduced and the strain rate was enhanced, the area after dynamic recrystallization was enhanced, and the average dynamically recrystallied grain size reduce. But the dynamically recrystallied grain size was not well-proportioned. In this paper the 350°C×1s-1 was suggested.

Download Full-text

The Mechanical Behavior of Zinc During Machining

Journal of Engineering Materials and Technology ◽

10.1115/1.2804526 ◽

1995 ◽

Vol 117 (2) ◽

pp. 172-178 ◽

Cited By ~ 23

Author(s):

Robin Stevenson ◽

David A. Stephenson

Keyword(s):

Flow Stress ◽

Strain Rate ◽

Mechanical Behavior ◽

Feed Rate ◽

Cutting Forces ◽

Material Flow ◽

Cutting Tool ◽

Cutting Conditions ◽

Extrapolation Method ◽

Compression Tests

It is well known that a nonzero force is obtained when cutting forces measured at different feed rates but otherwise constant cutting conditions are extrapolated to zero feed rate. In the literature, this nonzero intercept has been attributed to a ploughing effect associated with the finite sharpness of the cutting tool. However, the standard extrapolation method does not account for other variables such as strain, strain rate and temperature which also vary with feed rate and influence the work material flow stress. In this paper, the apparent flow stresses measured in high and low speed machining tests on zinc are compared with the flow stresses measured in compression tests. The results show that the flow stress measured in cutting is consistent with that measured in compression when all deformation variables are properly accounted for and that, contrary to the results obtained using the extrapolation approach, the ploughing force is negligible.

Download Full-text