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Theoretical and numerical studies of surface microstructural transformation in ultrasonic elliptical vibration cutting tungsten heavy alloys

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Abstract

Tungsten heavy alloy parts have significant applications in high-energy radiological fields. Under the extreme physical environment, the microstructure in the machined surface affects its radiation resistance. In this work, we concentrated upon the machined surface morphology evolution and surface microstructural transformation in ultrasonic elliptical vibration cutting the 95W-3.5Ni-1.5Fe alloy. Results identified that a nanometer-level roughness surface was generated under the particular combination of processing conditions. Corresponding to the ultra-precision machining experiments, a multiscale theoretical simulation framework involving the dislocation density change was employed to recognize the machined surface microstructures. The framework was presented by coupling a physical-based dislocation dynamic model with a finite element analysis model through calculating and calibrating the critical coefficients in dislocation density-based constitutive equation. An ultra-precision machining simulation model was developed to reveal the influence of different machining conditions, such as the cutting depth, feedrate, ultrasonic vibration amplitude, and frequency, on surface formation and dislocation density distribution characteristics. Finally, these predictions were compared with experimental findings utilizing SEM tests for validation purposes.

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Funding

This study is funded by the Sichuan Science and Technology Program (2021YJ0547).

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Authors and Affiliations

  1. Key Laboratory for Precision and Non-Traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, China

    Yanan Pan

  2. School of Mechanical Engineering, Southwest Jiaotong University, Chengdu, China

    Jinxuan Bai & Zhiwei Xu

Authors
  1. Yanan Pan
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  2. Jinxuan Bai
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  3. Zhiwei Xu
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Contributions

Experiment and manuscript: Yanan Pan. Conceptualization, methodology, simulation, and review: Jinxuan Bai. Characterization testing: Zhiwei Xu.

Corresponding author

Correspondence to Jinxuan Bai.

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All procedures performed in the present studies involving human participants were in accordance with the ethical standards of the institutional and national research committee and the 1964 Helsinki declaration, together with its later amendments or comparable ethical standards.

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Pan, Y., Bai, J. & Xu, Z. Theoretical and numerical studies of surface microstructural transformation in ultrasonic elliptical vibration cutting tungsten heavy alloys. Int J Adv Manuf Technol 123, 3943–3953 (2022). https://doi.org/10.1007/s00170-022-10293-1

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  • DOI: https://doi.org/10.1007/s00170-022-10293-1

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