Whole process analysis of microstructure evolution during chip formation of high-speed machining OFHC copper. (June 2021)

• Record Type: Journal Article
• Authors: Liu, Hongguang; Zhang, Jun; Xu, Binbin; Zhang, Huijie; Zhao, Wanhua
• Is Part Of: Journal of manufacturing processes. Volume 66(2021)
• Page Start: 470
• Page End: 482
• Publication Date: 2021-06
• Subjects: Chip formation -- Microstructure evolution -- High-speed machining -- Dynamic recrystallization; Production management -- Data processing -- Periodicals; Manufacturing processes -- Periodicals; Procestechnologie; Productietechniek; Production -- Gestion -- Informatique -- Périodiques; Fabrication -- Périodiques; Manufacturing processes; Production management -- Data processing; Periodicals; 670.5
• DOI: 10.1016/j.jmapro.2021.04.038
• Languages: English
• ISSNs: 1526-6125

Abstract

Graphical abstract: Highlights: In-depth analysis of microstructure evolution is performed through discretization of chip formation process. A coupled FE and CA approach with mixed mechanisms of cDRX and dDRX is applied for analysis of microstructure evolution. Roles of different DRX mechanisms are carried out within different stages of chip formation. Gradient distribution of microstructures within chips is dominantly influenced by pre-loading and loading conditions. Abstract: Higher cutting speed is always the pursuit of industries as it is one of the most effective methods to improve machining efficiency, which requires a better understanding of deformation and microstructure evolution process during chip formation. In this study, chip formation process is divided into three different sections of pre-loading, loading and unloading to analyze the mechanisms of microstructure evolution sequentially through a coupled finite element and cellular automata approach. The non-uniform distributed fields of strains, strain rates and temperatures induced by different stage during chip formation process are obtained and then transferred as boundary conditions for microstructure evolution. In pre-loading condition, microstructure evolution appears only along shear band with small sizes, which provides more boundaries for activation of DRX mechanisms in following conditions. Final microstructures always show a gradient distribution along shear direction, and secondary shear zone makes the greatest contribution to grain refinement. Average grain sizes and microstructure distribution have shown a good agreement between experimental data and simulation results, which indicates that this sequential simulation approach can perform a better description of those process characteristics of microstructure evolution during a continuous process with complicated boundary conditions.