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Title: Modelling of Tool Wear and Residual Stress during Machining of AISI H13 Tool Steel

Abstract

Residual stresses can enhance or impair the ability of a component to withstand loading conditions in service (fatigue, creep, stress corrosion cracking, etc.), depending on their nature: compressive or tensile, respectively. This poses enormous problems in structural assembly as this affects the structural integrity of the whole part. In addition, tool wear issues are of critical importance in manufacturing since these affect component quality, tool life and machining cost. Therefore, prediction and control of both tool wear and the residual stresses in machining are absolutely necessary. In this work, a two-dimensional Finite Element model using an implicit Lagrangian formulation with an automatic remeshing was applied to simulate the orthogonal cutting process of AISI H13 tool steel. To validate such model the predicted and experimentally measured chip geometry, cutting forces, temperatures, tool wear and residual stresses on the machined affected layers were compared. The proposed FE model allowed us to investigate the influence of tool geometry, cutting regime parameters and tool wear on residual stress distribution in the machined surface and subsurface of AISI H13 tool steel. The obtained results permit to conclude that in order to reduce the magnitude of surface residual stresses, the cutting speed should be increased, themore » uncut chip thickness (or feed) should be reduced and machining with honed tools having large cutting edge radii produce better results than chamfered tools. Moreover, increasing tool wear increases the magnitude of surface residual stresses.« less

Authors:
;  [1]; ;  [2]
  1. X-Ray Diffraction Centre for Materials Research, University of Coimbra, P-3004 516 Coimbra (Portugal)
  2. Department of Mechanical Engineering, University of Calabria 87036 Rende (Italy)
Publication Date:
OSTI Identifier:
21057341
Resource Type:
Journal Article
Resource Relation:
Journal Name: AIP Conference Proceedings; Journal Volume: 908; Journal Issue: 1; Conference: NUMIFORM '07: 9. international conference on numerical methods in industrial forming processes, Porto (Portugal), 17-21 Jun 2007; Other Information: DOI: 10.1063/1.2740966; (c) 2007 American Institute of Physics; Country of input: International Atomic Energy Agency (IAEA)
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; COMPUTERIZED SIMULATION; CRACKING; CREEP; CUTTING; DISTRIBUTION; FATIGUE; FINITE ELEMENT METHOD; LAGRANGIAN FUNCTION; LAYERS; LOADING; MANUFACTURING; RESIDUAL STRESSES; STEELS; STRESS CORROSION; SURFACES; TWO-DIMENSIONAL CALCULATIONS; WEAR

Citation Formats

Outeiro, Jose C., Pina, Jose C., Umbrello, Domenico, and Rizzuti, Stefania. Modelling of Tool Wear and Residual Stress during Machining of AISI H13 Tool Steel. United States: N. p., 2007. Web. doi:10.1063/1.2740966.
Outeiro, Jose C., Pina, Jose C., Umbrello, Domenico, & Rizzuti, Stefania. Modelling of Tool Wear and Residual Stress during Machining of AISI H13 Tool Steel. United States. doi:10.1063/1.2740966.
Outeiro, Jose C., Pina, Jose C., Umbrello, Domenico, and Rizzuti, Stefania. Thu . "Modelling of Tool Wear and Residual Stress during Machining of AISI H13 Tool Steel". United States. doi:10.1063/1.2740966.
@article{osti_21057341,
title = {Modelling of Tool Wear and Residual Stress during Machining of AISI H13 Tool Steel},
author = {Outeiro, Jose C. and Pina, Jose C. and Umbrello, Domenico and Rizzuti, Stefania},
abstractNote = {Residual stresses can enhance or impair the ability of a component to withstand loading conditions in service (fatigue, creep, stress corrosion cracking, etc.), depending on their nature: compressive or tensile, respectively. This poses enormous problems in structural assembly as this affects the structural integrity of the whole part. In addition, tool wear issues are of critical importance in manufacturing since these affect component quality, tool life and machining cost. Therefore, prediction and control of both tool wear and the residual stresses in machining are absolutely necessary. In this work, a two-dimensional Finite Element model using an implicit Lagrangian formulation with an automatic remeshing was applied to simulate the orthogonal cutting process of AISI H13 tool steel. To validate such model the predicted and experimentally measured chip geometry, cutting forces, temperatures, tool wear and residual stresses on the machined affected layers were compared. The proposed FE model allowed us to investigate the influence of tool geometry, cutting regime parameters and tool wear on residual stress distribution in the machined surface and subsurface of AISI H13 tool steel. The obtained results permit to conclude that in order to reduce the magnitude of surface residual stresses, the cutting speed should be increased, the uncut chip thickness (or feed) should be reduced and machining with honed tools having large cutting edge radii produce better results than chamfered tools. Moreover, increasing tool wear increases the magnitude of surface residual stresses.},
doi = {10.1063/1.2740966},
journal = {AIP Conference Proceedings},
number = 1,
volume = 908,
place = {United States},
year = {Thu May 17 00:00:00 EDT 2007},
month = {Thu May 17 00:00:00 EDT 2007}
}
  • In general, the flow stress models used in computer simulation of machining processes are a function of effective strain, effective strain rate and temperature developed during the cutting process. However, these models do not adequately describe the material behavior in hard machining, where a range of material hardness between 45 and 60 HRC are used. Thus, depending on the specific material hardness different material models must be used in modeling the cutting process. This paper describes the development of a hardness-based flow stress and fracture models for the AISI H13 tool steel, which can be applied for range of materialmore » hardness mentioned above. These models were implemented in a non-isothermal viscoplastic numerical model to simulate the machining process for AISI H13 with various hardness values and applying different cutting regime parameters. Predicted results are validated by comparing them with experimental results found in the literature. They are found to predict reasonably well the cutting forces as well as the change in chip morphology from continuous to segmented chip as the material hardness change.« less
  • No abstract prepared.
  • In the present work, surface modifications generated by the low energy high current pulsed electron beam (LEHCPEB) treatments have been investigated on an AISI H13 (4Cr5MoSiV) steel. From the observations of scanning electron microscopy, x-ray diffraction, and electron back scattering diffraction determinations, it could be established that the final structure in the melted layer is a mixture of ultrafine {delta} phase, martensite, and residual austenite. The formation of the heterogeneous microstructures on the surface layer is related to the very rapid heating, melting, solidification, and cooling induced by the LEHCPEB irradiation. After the LEHCPEB treatment, the wear resistance of themore » steel effectively improved. This can be mainly attributed to the higher hardness of the ultrafine structures formed on the top surface and the hardened subsurface layers after the treatment.« less
  • AISI 1018 steel substrates were powder-pack, diffusion boronized at 850 C for 4 h, followed by air quenching. Optical microscopy in conjunction with color etching was used to obtain the average penetration depth of the iron monoboride layer (9 {micro}m) and the iron diboride layer (57 {micro}m). X-ray diffraction by synchrotron radiation, conducted at the National Synchrotron Light Source in Brookhaven National Laboratory, confirmed the presence of iron monoboride and iron diboride in the boronized plain steel substrates. The sin{sup 2} {Psi} technique was employed to calculate the residual stress found in the iron monoboride layer (-237 MPa) and inmore » the substrate layer (-150 MPa) that is intertwined with the needle-like, iron diboride penetration.« less