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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}
}