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Step-dependent grain refinement and micro-harness evolution during chip formation process in orthogonal cutting of titanium alloy Ti-6Al-4V

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Abstract

In the two-step cutting process, the material deformation behavior of the subsequent cutting step is affected by the micro-structural properties of machined surface layer produced by the previous cutting step, among which the grain refinement and micro-hardness evolution are particularly highlighted. This study aims to explore the influence of cutting step on grain refinement and work hardening in machined chips of Ti-6Al-4V alloy. A two-step cutting finite element method (FEM) simulation model combining the Abaqus user subroutine of Zener-Hollomon and Hall–Petch model was established to investigate the chip formation; the temperature evolution, the grain size and the resulting micro-hardness, and the accuracy of the proposed simulation model was validated by comparing the chip morphological parameters with the machining experiments. The grain size and micro-hardness distribution in the formed chips under different cutting speeds and cutting steps were analyzed. The results confirmed that the residual strains in the previous step led to the variation of grain size and micro-hardness of the chip free surface in the second cutting step. At the same time, this influences the grain refinement process in the shear bands. What is more, at the higher cutting speed, the smaller the deformation zone in the chip free surface is, the smaller grain sizes and the higher micro-hardness in primary shear zone were identified.

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Availability of data and material

The datasets generated and analyzed during the current study are available from the corresponding author on reasonable request.

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Funding

Financial support was provided by the Natural Science Foundation of Shandong Province (ZR2021ME043), the National Natural Science Foundation of China (51605260), the Key Research and Development Program of Shandong Province (2019JZZY010114), and the Young Scholars Program of Shandong University (2018WLJH57).

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Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Minghang Lv, Anhai Li, Dejun Ge & Rufeng Zhang

  2. National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan, 250061, China

    Minghang Lv, Anhai Li, Dejun Ge & Rufeng Zhang

Authors
  1. Minghang Lv
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  2. Anhai Li
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  3. Dejun Ge
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  4. Rufeng Zhang
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Contributions

Conceptualization, M.L. and A.L.; methodology, M.L., A.L., and R.Z.; software, M.L., R.Z., and D.G.; validation, M.L., A.L., and R.Z.; formal analysis, M.L. and A.L.; investigation, M.L., A.L., and R.Z.; data curation, M.L., R.Z., and D.G.; writing—original draft preparation, M.L.; writing—review and editing, M.L. and A.L.; visualization, M.L., R.Z., and D.G.; supervision, A.L.; project administration, A.L.; funding acquisition, A.L. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Anhai Li.

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Lv, M., Li, A., Ge, D. et al. Step-dependent grain refinement and micro-harness evolution during chip formation process in orthogonal cutting of titanium alloy Ti-6Al-4V. Int J Adv Manuf Technol 119, 4219–4236 (2022). https://doi.org/10.1007/s00170-021-08511-3

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