Process and Microstructure in Materials-Affected Manufacturing

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


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.


Machining Microstructure Flow stress Force Residual stress 


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Copyright information

© Springer International Publishing AG 2017

Authors and Affiliations

  1. 1.Woodruff School of Mechanical EngineeringGeorgia Institute of TechnologyAtlantaUSA

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