Microstructure investigation of dynamic recrystallization in hard machining: From thermodynamic irreversibility perspective

Abstract

The drastically changed thermal, mechanical, and chemical energies within the machined surface layer during hard machining tend to initiate microstructural alteration. In this paper, attention is paid to the introduction of thermodynamic potential to unravel the mechanism of microstructure evolution. First, the thermodynamic potential-based model expressed by the Helmholtz free energy was proposed for predicting the microstructure changes of serrated chip and the machined surface layer. Second, the proposed model was implemented into a validated finite element simulation model for cutting operation as a user-defined subroutine. In addition, the predicted irreversible thermodynamic state change in the deformation zones associated with grain size, which was reduced to less than 1 mm from the initial size of 1.5 mm on the machined surface, was provided for an in-depth explanation. The good consistency between the simulated results and experimental data validated the efficacy of the developed model. This research helps to provide further insight into the microstructure alteration during metal cutting.

Graphical abstract

Keywords

thermodynamic irreversibility / Helmholtz free energy / microstructure evolution / dynamic recrystallization / hard milling

References

[1] Zhu J, Lin G T, Zhang Z H, The martensitic crystallography and strengthening mechanisms of ultra-high strength rare earth H13 steel. Materials Science and Engineering A, 2020, 797: 140139

[2] Vishal R, Nimel Sworna Ross K, Manimaran G, Impact on machining of AISI H13 steel using coated carbide tool under vegetable oil minimum quantity lubrication. Materials Performance and Characterization, 2019, 8(1): 527–537

[3] Devillez A, Le Coz G, Dominiak S, Dry machining of Inconel 718, workpiece surface integrity. Journal of Materials Processing Technology, 2011, 211(10): 1590–1598

[4] Kaynak Y, Tobe H, Noebe R D, The effects of machining on the microstructure and transformation behavior of NiTi alloy. Scripta Materialia, 2014, 74: 60–63

[5] Chen Y, Yang Y, Feng Z, Surface gradient nanostructures in high speed machined 7055 aluminum alloy. Journal of Alloys and Compounds, 2017, 726: 367–377

[6] Ramesh A, Melkote S N, Allard L F, Analysis of white layers formed in hard turning of AISI 52100 steel. Materials Science and Engineering A, 2005, 390(1–2): 88–97

[7] Bosheh S S, Mativenga P T. White layer formation in hard turning of H13 tool steel at high cutting speeds using CBN tooling. International Journal of Machine Tools and Manufacture, 2006, 46(2): 225–233

[8] Aramcharoen A, Mativenga P T. White layer formation and hardening effects in hard turning of H13 tool steel with CrTiAlN and CrTiAlN/MoST-coated carbide tools. International Journal of Advanced Manufacturing Technology, 2008, 36(7–8): 650–657

[9] Wang F, Zhao J, Li A, Effects of cutting conditions on microhardness and microstructure in high-speed milling of H13 tool steel. International Journal of Advanced Manufacturing Technology, 2014, 73(1–4): 137–146

[10] Han S, Melkote S N, Haluska M S, White layer formation due to phase transformation in orthogonal machining of AISI 1045 annealed steel. Materials Science and Engineering A, 2008, 488(1–2): 195–204

[11] Zhang H, Shen X, Bo A, A multiscale evaluation of the surface integrity in boring trepanning association deep hole drilling. International Journal of Machine Tools and Manufacture, 2017, 123: 48–56

[12] Yang D, Liu Z. Surface plastic deformation and surface topography prediction in peripheral milling with variable pitch end mill. International Journal of Machine Tools and Manufacture, 2015, 91: 43–53

[13] Zhang F, Duan C, Sun W, Effects of cutting conditions on the microstructure and residual stress of white and dark layers in cutting hardened steel. Journal of Materials Processing Technology, 2019, 266: 599–611

[14] Zhang S, Guo Y B. An experimental and analytical analysis on chip morphology, phase transformation, oxidation, and their relationships in finish hard milling. International Journal of Machine Tools and Manufacture, 2009, 49(11): 805–813

[15] Wang Q, Liu Z, Wang B, Stress-induced orientation relationship variation for phase transformation of, α-Ti to β-Ti during high speed machining Ti-6Al-4V. Materials Science and Engineering A, 2017, 690: 32–36

[16] Wan Z P, Zhu Y E, Liu H W, Microstructure evolution of adiabatic shear bands and mechanisms of saw-tooth chip formation in machining Ti6Al4V. Materials Science and Engineering A, 2012, 531: 155–163

[17] Courbon C, Mabrouki T, Rech J, Further insight into the chip formation of ferritic-pearlitic steels: Microstructural evolutions and associated thermo-mechanical loadings. International Journal of Machine Tools and Manufacture, 2014, 77: 34–46

[18] Bejjani R, Balazinski M, Attia H, Chip formation and microstructure evolution in the adiabatic shear band when machining titanium metal matrix composites. International Journal of Machine Tools and Manufacture, 2016, 109: 137–146

[19] Medina-Clavijo B, Saez-De-Buruaga M, Motz C, Microstructural aspects of the transition between two regimes in orthogonal cutting of AISI 1045 steel. Journal of Materials Processing Technology, 2018, 260: 87–96

[20] Rinaldi S, Umbrello D, Rotella G, A physically based model to predict microstructural modifications in Inconel 718 high speed machining. Procedia Manufacturing, 2020, 47: 487–492

[21] Ding H, Shen N, Shin Y C. Modeling of grain refinement in aluminum and copper subjected to cutting. Computational Materials Science, 2011, 50(10): 3016–3025

[22] Xu X, Zhang J, Outeiro J, Multiscale simulation of grain refinement induced by dynamic recrystallization of Ti6Al4V alloy during high speed machining. Journal of Materials Processing Technology, 2020, 286: 116834

[23] Ding H, Shin Y C. A metallo-thermo-mechanically coupled analysis of orthogonal cutting of AISI 1045 steel. Journal of Manufacturing Science and Engineering, 2012, 134(5): 051014

[24] Sadeghifar M, Javidikia M, Songmene V, Finite element simulation-based predictive regression modeling and optimum solution for grain size in machining of Ti6Al4V alloy: Influence of tool geometry and cutting conditions. Simulation Modelling Practice and Theory, 2020, 104: 102141

[25] Buchkremer S, Klocke F. Modeling nanostructural surface modi-fications in metal cutting by an approach of thermodynamic irreversibility: Derivation and experimental validation. Continuum Mechanics and Thermodynamics, 2017, 29(1): 271–289

[26] Lucas K. Thermodynamics: The Basic Laws of Energy and Material Conversion. Berlin: Springer, 2008

[27] Johnson G R, Cook W H. Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Engineering Fracture Mechanics, 1985, 21(1): 31–48

[28] Nasr M N A, Ng E G, Elbestawi M A. A modified time-efficient FE approach for predicting machining-induced residual stresses. Finite Elements in Analysis and Design, 2008, 44(4): 149–161

[29] Murr L E. Interfacial Phenomena in Metals and Alloys. Upper Saddle River: Wesley Publishing Company, 1974

[30] Poliak E I, Jonas J J. A one-parameter approach to determining the critical conditions for the initiation of dynamic recrystallization. Acta Materialia, 1996, 44(1): 127–136

[31] Meyers M A, Nesterenko V F, Lasalvia J C, Shear localization in dynamic deformation of materials: microstructural evolution and self-organization. Materials Science and Engineering A, 2001, 317(1–2): 204–225

[32] Wang C, Ding F, Tang D, Modeling and simulation of the high-speed milling of hardened steel SKD11 (62 HRC) based on SHPB technology. International Journal of Machine Tools and Manufacture, 2016, 108: 13–26

[33] Fu H J, Devor R E, Kapoor S G. A mechanistic model for the prediction of the force system in face milling operations. Journal of Engineering for Industry, 1984, 106(1): 81–88

[34] Tang D W, Wang C Y, Hu Y N, Finite-element simulation of conventional and high-speed peripheral milling of hardened mold steel. Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science, 2009, 40(13): 3245–3257

[35] Ding H, Shen N, Shin Y C. Experimental evaluation and modeling analysis of micromilling of hardened H13 tool steels. Journal of Manufacturing Science and Engineering, 2011, 133(4): 041007

[36] Zhang X, Wu S, Wang H, Predicting the effects of cutting parameters and tool geometry on hard turning process using finite element method. Journal of Manufacturing Science & Engineering, 2011, 133(4): 041010

[37] Li B, Zhang S, Zhang Q, Modelling of phase transformations induced by thermo-mechanical loads considering stress-strain effects in hard milling of AISI H13 steel. International Journal of Mechanical Sciences, 2018, 149: 241–253

[38] Morito S, Yoshida H, Maki T, Effect of block size on the strength of lath martensite in low carbon steels. Materials Science and Engineering: A, 2006, 438–440: 237–240

[39] Duan C Z, Zhang L C. Adiabatic shear banding in AISI 1045 steel during high speed machining: Mechanisms of microstructural evolution. Materials Science and Engineering A, 2012, 532: 111–119

[40] Poorganji B, Yamaguchi T, Maki T, Formation of ultrafine grained ferrite by warm deformation of tempered lath martensite inlow alloy steels. Materials Science Forum, 2007, 558–559: 557–562

[41] Xu Y, Bai Y, Meyers M A. Deformation, phase transformation and recrystallization in the shear bands induced by high-strain rate loading in titanium and its alloys. Journal of Materials Processing Technology, 2006, 22(6): 737–746

[42] Andrade U, Meyers M A, Vecchio K S, Dynamic recrystallization in high-strain, high-strain-rate plastic deformation of copper. Acta Metallurgica et Materialia, 1994, 42(9): 3183–3195

[43] Ding R, Knaggs C, Li H, Characterization of plastic deformation induced by machining in a Ni-based superalloy. Materials Science and Engineering: A, 2020, 778: 139104

[44] Zhang F Y, Duan C Z, Wang M J, White and dark layer formation mechanism in hard cutting of AISI52100 steel. Journal of Manufacturing Processes, 2018, 32: 878–887

RIGHTS & PERMISSIONS

Higher Education Press