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Finite element modelling of combined turning/burnishing effects on surface integrity of Ti6Al4V alloy

Abstract

This paper presents a physics-based model able to simulate the flow stress behavior of the Ti6Al4V alloy during subsequent severe plastic deformation processes, namely turning and burnishing. All the physical and metallurgical mechanisms that accommodate the deformation were considered to describe the material strengthening and they were implemented via user subroutine in a commercial finite element software. Then, the proposed numerical model was used to investigate the effect of combined turning/burnishing processes on the surface integrity of manufactured Ti6Al4V components. Turning and roller burnishing experiments were conducted to validate the proposed finite element model and to analyze the microstructural phenomena and the output variables. The implemented model well fits experimental results, precisely predicting the evolution of grain size, dislocations, hardness, and residual stresses. Different process combinations can lead to similar microstructures and information on different contributions can be highlighted through physics-based modelling and simulated process combinations.

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Funding

This research was supported by Ministry of Education, University and Research—MIUR within the PRIN 2017 project “Surface functionalization to improve triBo-corrosIOn performaNces of metal Implants through advanCed machining operations—BIONIC” (Project code: 201742RB8R).

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Contributions

Giovanna Rotella: conceptualization lead), data curation (supporting), formal analysis (supporting), funding acquisition (equal), investigation (equal), methodology (lead), project administration (supporting), resources (equal), software (supporting), supervision (lead), validation (supporting), writing – original draft (equal), writing – review and editing (equal).

Maria Rosaria Saffioti: conceptualization (supporting), data curation (lead), formal analysis (supporting), funding acquisition (supporting), investigation (equal), methodology (equal), project administration (supporting), resources (supporting), software (lead), supervision (supporting), validation (lead), writing – original draft (equal), writing – review and editing (supporting).

Michela Sanguedolce: conceptualization (supporting), data curation (lead), formal analysis (supporting), funding acquisition (supporting), investigation (equal), methodology (equal), project administration (supporting), resources (supporting), software (lead), supervision (supporting), validation (lead), writing – original draft (equal), writing – review and editing (supporting).

Domenico Umbrello: conceptualization (equal), data curation (supporting), formal analysis (supporting), funding acquisition (lead), investigation (equal), methodology (equal), project administration (lead), resources (equal), software (supporting), supervision (lead), validation (supporting), writing – original draft (equal), writing – review and editing (equal).

Corresponding author

Correspondence to Giovanna Rotella.

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Rotella, G., Saffioti, M.R., Sanguedolce, M. et al. Finite element modelling of combined turning/burnishing effects on surface integrity of Ti6Al4V alloy. Int J Adv Manuf Technol (2021). https://doi.org/10.1007/s00170-021-08219-4

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Keywords

  • Finite element method
  • Surface integrity
  • Titanium
  • Physics-based model
  • Machining
  • Burnishing