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Force prediction in micro-grinding maraging steel 3J33b considering the crystallographic orientation and phase transformation

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Abstract

In micro-grinding, the effects of crystallography on grinding force become significant since the depth of cut is of the same order as the grain size. In this research, the Taylor factor model for multi-phase materials is proposed based on the previously reported Taylor factor model for monocrystalline material. Based on this model, the flow stress model is developed, which takes both the effect of CO on the athermal stress and the stress induced by the phase transformation into account. Based on the flow stress model, the predictive model of chip formation force is proposed by adapting parallel-sided shear zone theory. The rubbing force is modeled by applying Waldorf’s worn tool theory. Furthermore, the plowing force is predicted based on previously reported model by the authors. Subsequently, a comprehensive model of the micro-grinding force is proposed by considering mechanical-thermal loading, the effects of crystallography, and phase transformation. Finally, the model is validated by conducting an orthogonal-designed experiment with the result proving that the prediction of the model is capable to capture the magnitude and trend of the experimental data. Moreover, the proposed analysis are compared with the predictions of two other previously reported models with the result, indicating that the model that considers the effect of CO and the phase transformation improves the accuracy of the micro-grinding force.

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Abbreviations

A, B, C, m, n :

Johnson-Cook parameters

HV:

Vickers hardness

HB:

Brignell hardness

α 1 :

Material constant

b 1 :

Burger vector

ρ 1 :

Density of dislocation

ρ :

Material density

K :

Thermal conductivity

T 0, T m, T w :

Workpiece, ambient, and melting temperature

C p :

Specific heat

v :

Poisson’s ratio

V :

Wheel speed

V w :

Workpiece speed or feedrate

a p :

The depth of cut

l c :

The total contact length of the primary heat source

l ob :

Contact length of the plowing plane

l ab :

Contact length of the shear plane

l oc :

Contact length of the rubbing plane

α cr :

The critical rake angle

φ k :

Local shear angle

α k :

Local rake angle

β k :

Local friction angle

τ s :

Shear strength in tangential direction

t :

Undeformed chip thickness

f :

Phase transformation fraction

D :

Grit diameter

C s :

Static cutting edge density

C d :

Dynamic cutting edge density

Φ1i, Φ2i :

Angle between slip plane and cutting plane in grain

γ1, γi :

Correction angles

E :

Workpiece elasticity modulus

K w, K t :

Workpiece and wheel elasticity

F tg, rubbing :

Tangential force of single grit

F ng, rubbing :

Normal force of single grit

F t, plowing :

Tangential plowing force of the whole wheel

F n, plowing :

Normal plowing force of the whole wheel

F t, shear :

Tangential shear force of the whole wheel

F n, shear :

Normal shear force of the whole wheel

F t, rubbing :

Tangential force of the whole wheel

F n, rubbing :

Normal force of the whole wheel

k, m, t :

Functions of temperature, stain, and strain rate

φ 1, ∅, φ 2 :

Bunge Euler angles

ΔT wk :

Workpiece temperature rise

w :

Cutting width

θ :

The angle shear force and normal force on the shear plane

r :

The cutting edge radius

t cr :

The minimum undeformed chip thickness

k :

A chip formation point on the grit edge

M F, M B :

Taylor factor of single FCC and BCC crystal

M :

Taylor factor of muti-phase material

A s, k s :

Parameters of wheel topography

\( {\dot{\varepsilon}}_0 \) :

Material constant

ε cp :

Plastic strain

\( \dot{\varepsilon} \) :

Plastic strain rate

ε tp :

Strain induced by phase transformation

ψ :

The cone angle of grit

α :

Thermal diffusivity

σ :

Total flow stress

Ω1i, Ω2i :

Angle between slip direction and cutting direction in grain

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Acknowledgments

The authors would like to acknowledge the National Natural Science Foundation of China (Grant No. 51705073).

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Authors and Affiliations

  1. School of Mechanical Engineering, Donghua University, Shanghai, 201620, China

    Man Zhao, Xia Ji & Steven Y. Liang

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

    Man Zhao & Steven Y. Liang

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  1. Man Zhao
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  2. Xia Ji
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Correspondence to Xia Ji.

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Zhao, M., Ji, X. & Liang, S.Y. Force prediction in micro-grinding maraging steel 3J33b considering the crystallographic orientation and phase transformation. Int J Adv Manuf Technol 103, 2821–2836 (2019). https://doi.org/10.1007/s00170-019-03724-z

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