Skip to main content
SpringerLink
Log in

Process and Microstructure in Materials-Affected Manufacturing

  • Conference paper
  • First Online:
Proceedings of 5th International Conference on Advanced Manufacturing Engineering and Technologies (NEWTECH 2017)

Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

  • 1317 Accesses

Abstract

The fundamental understanding of manufacturing processes has been long focused on the geometric, mechanic, and thermal aspects leading to the product shape and finish. However, the effects of process mechanics attributing to material microstructural properties and constitutive characteristics are essential but not yet well understood due to the intricacy of multiple scale process-materials interaction physics. Further, the effects of materials mechanics on the process behaviors, in the context of stress and heat generations, carries significant practical relevance but has not been fully addressed in science. This is to state that manufacturing processes, such as metal forging, polymer compression modeling, 3-D printing, et al., commonly involve a significant amount of mechanical, thermal, and even chemical loadings that interact strongly with part material microstructural evolutions, which in turn determine the performance and functionality beyond just the shape and finish of the end products. On the other hand, the materials microstructure in terms of grain size, texture, phase field, etc. can also change the stress and heat generation mechanics of the manufacturing process. The scope of this paper is to present the “materials-affected manufacturing” connotation in exploring how process mechanics and materials mechanics interact retroactively with each other, and based upon this connotation better predictions of force, temperature, residual stress, and final part properties and functionalities can be possible. The materials-affected manufacturing analysis methodology involves an iterative blending scheme in combining microstructural synthesis and material homogenization analysis to allow for the interactive effects of materials dynamics and processing mechanics to be considered simultaneously. This paper discusses the basic formulation, computational configuration, and experimental validation in the example cases of machining operations with material recrystallization, grain size variation, recrystallization, texture, and phase field in consideration. Explicit calculation of material microstructure evolution path is provided as functions of process parameters and materials attributes. To factor the material microstructure states into the thermo-mechanical coupling process, the material microstructure terms are introduced into the traditional material constitutive model with hardened steels and titanium alloys as examples. Results show that residual stresses and machining forcescan be better modeled and predicted in the materials-affected manufacturing analysis platform.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 129.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 169.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

References

  1. Lim EM, Menq CH (1997) Integrated planning for precision machining of complex surfaces. Part 1: cutting-path and feedrate optimization. Int J Mach Tools Manuf 37(1):61–75

    Article  Google Scholar 

  2. Cheung CF, Lee WB (2000) A multi-spectrum analysis of surface roughness formation in ultra-precision machining. Precision Engineering 24(1):77–87

    Article  Google Scholar 

  3. Picard YN et al (2003) Focused ion beam-shaped microtools for ultra-precision machining of cylindrical components. Precis Eng 27(1):59–69

    Article  Google Scholar 

  4. Ulutan D, Ozel T (2011) Machining induced surface integrity in titanium and nickel alloys: a review. Int J Mach Tools Manuf 51(3):250–280

    Article  Google Scholar 

  5. Pan Z et al (2016) Analytical model for force prediction in laser-assisted milling of IN718. Int J Adv Manuf Technol. doi:10.1007/s00170-016-9629-6

    Google Scholar 

  6. Lei S, Liu W (2002) High-speed machining of titanium alloys using the driven rotary tool. Int J Mach Tools Manuf 42(6):653–661

    Article  Google Scholar 

  7. Pan Z et al (2017) Modeling of Ti–6Al–4V machining force considering material microstructure evolution. Int J Adv Manuf Technol. doi:10.1007/s00170-016-9964-7

    Google Scholar 

  8. Fergani O et al (2016) Microstructure texture prediction in machining processes. Procedia CIRP 46:595–598

    Article  Google Scholar 

  9. Ghosh S, Kain V (2010) Microstructural changes in AISI 304L stainless steel due to surface machining: effect on its susceptibility to chloride stress corrosion cracking. J Nucl Mater 403(1):62–67

    Google Scholar 

  10. Barbacki A, Kawalec M, Hamrol A (2003) Turning and grinding as a source of micro structural changes in the surface layer of hardened steel. J Mater Process Technol 133(1):21–25

    Article  Google Scholar 

  11. Lu C (2008) Study on prediction of surface quality in machining process. J Mater Process Technol 205(1):439–450

    Article  Google Scholar 

  12. Zhipeng Pan AT, Shih DS, Garmestani H, Liang SY (2017) The Effects of Dynamic Evolution of Microstructure on Machining Forces. In: Proceedings of the institution of mechanical engineers, Part B: Journal of Engineering Manufacture

    Google Scholar 

  13. Xu HH, Jahanmir S (1994) Effect of microstructure on abrasive machining of advanced ceramics. In: A collection of papers presented at the 96th annual meeting and the 1994 fall meetings of the materials and equipment/Whitewares/Refractory Ceramics/Basic Science: Ceramic Engineering and Science Proceedings, Vol. 16, Issue 1. 1995. Wiley Online Library

    Google Scholar 

  14. Chou YK, Evans CJ (1999) White layers and thermal modeling of hard turned surfaces. Int J Mach Tools Manuf 39(12):1863–1881

    Article  Google Scholar 

  15. Swaminathan S et al (2007) Severe plastic deformation of copper by machining: microstructure refinement and nanostructure evolution with strain. Scripta Mater 56(12):1047–1050

    Article  Google Scholar 

  16. Filip R et al (2003) The effect of microstructure on the mechanical properties of two-phase titanium alloys. J Mater Process Technol 133(1):84–89

    Article  Google Scholar 

  17. Gil F et al (2001) Formation of α-Widmanstätten structure: effects of grain size and cooling rate on the Widmanstätten morphologies and on the mechanical properties in Ti–6Al–4V alloy. J Alloy Compd 329(1):142–152

    Article  Google Scholar 

  18. Kugler G, Turk R (2004) Modeling the dynamic recrystallization under multi-stage hot deformation. Acta Mater 52(15):4659–4668

    Article  Google Scholar 

  19. Suárez A et al (2004) Modeling of phase transformations of Ti–6Al–4V during laser metal deposition. Physics Procedia 12:666–673

    Article  Google Scholar 

  20. Malinov S et al (2001) Differential scanning calorimetry study and computer modeling of β ⇒ α phase transformation in a Ti–6Al–4V alloy. Metall Mat Trans A 32(4):879–887

    Article  Google Scholar 

  21. Ducato A, Fratini L, Micari F (2013) Prediction of phase transformation of Ti–6Al–4V titanium alloy during hot-forging processes using a numerical model. In: Proceedings of the institution of mechanical engineers, Part L: Journal of Materials Design and Applications, p. 1464420713477344

    Google Scholar 

  22. Jiles D (1988) The effect of compressive plastic deformation on the magnetic properties of AISI 4130 steels with various microstructures. J Phys D Appl Phys 21(7):1196

    Article  Google Scholar 

  23. Ji X et al (2014) Modeling the effects of minimum quantity lubrication on machining force, temperature, and residual stress. Mach Sci Technol 18(4):547–564

    Article  Google Scholar 

  24. Grum J, Kisin M (2003) Influence of microstructure on surface integrity in turning—Part II: the influence of a microstructure of the workpiece material on cutting forces. Int J Mach Tools Manuf 43:1545–1551

    Google Scholar 

  25. Gibbs RK Hodgson PD (1992) A mathematical model to predict the mechanical properties of the hot rolled C–Mn and microalloyed steels. ISIJ Int 32(12):10

    Google Scholar 

  26. Hawbolt EB, Sun WP (1997) Comparison between Static and Metadynamic Recrystallization an application to the hot rolling of steels. ISIJ Int 37(10):1000–1009

    Google Scholar 

  27. Sajadi SV, Ketabchi M, Nourani MR (2010) Hot deformation characteristics of 34CrMo4 steel. J Iron Steel Res Int 17(12):65–69

    Google Scholar 

  28. Xia Ji XZ, Li Beizhi, Liang Steven Y (2014) Modeling the effects of minimum quantity lubrication on machining force, temperature, and residual stress. Mach Sci Technol Int J 18(4):547–564

    Article  Google Scholar 

  29. Srinivasa YV, Shunmugam MS (2013) Mechanistic model for prediction of cutting forces in micro end-milling and experimental comparison. Int J Mach Tools Manuf 67:18–27

    Google Scholar 

  30. Kim DH, Lee CM (2014) A study of cutting force and preheating-temperature prediction for laser-assisted milling of Inconel 718 and AISI 1045 steel. Int J Heat Mass Transf 71:264–274

    Article  Google Scholar 

  31. Roucoules C, Hodgson P (1995) Post-dynamic recrystallisation after multiple peak dynamic recrystallisation in C–Mn steels. Mater Sci Technol 11(6):548–556

    Article  Google Scholar 

  32. Johnson GR, Cook WH (1983) A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. In: Proceedings of the 7th international symposium on ballistics, The Hague, The Netherlands

    Google Scholar 

  33. Calamaz M, Coupard D, Girot F (2008) A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti–6Al–4V. Int J Mach Tools Manuf 48(3):275–288

    Google Scholar 

  34. Zhang X, Shivpuri R, Srivastava A (2014) Role of phase transformation in chip segmentation during high speed machining of dual phase titanium alloys. J Mater Process Technol 214(12):3048–3066

    Article  Google Scholar 

  35. Shivpuri R et al (2002) Microstructure-mechanics interactions in modeling chip segmentation during titanium machining. CIRP Ann Manuf Technol 51(1):71–74

    Article  Google Scholar 

  36. Pan Z et al (2016) Prediction of machining-induced phase transformation and grain growth of Ti–6Al–4V alloy. Int J Adv Manuf Technol 87(1):859–866

    Article  Google Scholar 

  37. Ratchev S et al (2011) Mathematical modelling and integration of micro-scale residual stresses into axisymmetric FE models of Ti–6Al–4V alloy in turning. CIRP J Manuf Sci Technol 4(1):80–89

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA, 30332, USA

    Steven Y. Liang & Zhipeng Pan

Authors
  1. Steven Y. Liang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhipeng Pan
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Steven Y. Liang .

Editor information

Editors and Affiliations

  1. University Belgrade , Belgrade, Serbia

    Vidosav Majstorovic

  2. University of Belgrade , Belgrade, Serbia

    Zivana Jakovljevic

Rights and permissions

Reprints and permissions

Copyright information

© 2017 Springer International Publishing AG

About this paper

Cite this paper

Liang, S.Y., Pan, Z. (2017). Process and Microstructure in Materials-Affected Manufacturing. In: Majstorovic, V., Jakovljevic, Z. (eds) Proceedings of 5th International Conference on Advanced Manufacturing Engineering and Technologies. NEWTECH 2017. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-319-56430-2_23

Download citation

  • DOI: https://doi.org/10.1007/978-3-319-56430-2_23

  • Published:

  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-319-56429-6

  • Online ISBN: 978-3-319-56430-2

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics

Search

Navigation