Evaluation of different flow stress laws coupled with a physical based ductile failure criterion for the modelling of the chip formation process of Ti-6Al-4V under broaching conditions

During the machining of Ti-6Al-4V the changing deformation mechanisms produce a complex microstructure of segmented chips, which directly influenced tool-wear and process stability. Numerical simulation could give an insight into the physical phenomena involved in chip segmentation, but its accuracy is directly related to the reliability of the input parameters. In this work, therefore, three different flow stress law were evaluated coupled with a physical based ductile failure criterion, which depends on stress triaxiality and temperature. To this end, the flow stress laws were implemented in the finite element software AdvantEdge by programming user-defined subroutines. The resulting FEM models were compared with orthogonal cutting experimental tests (tubular/linear), analyzing different fundamental outputs (machining forces, temperatures in the workpiece and chip morphology). All the FEM models showed good agreement with the experimental results

Mechanical properties of friction induced nanocrystalline pearlitic steel

Nanocrystalline structured variants of commercially available alloys have shown potential for boosting the mechanical properties of these materials, leading to a reduction in waste and thereby retaining feasible supply chains. One approach towards achieving these nanostructures resides in frictional treatments on manufactured parts, leading to differential refinement of the surface structure as compared to the bulk material. In this work the machining method is considered to be a testing platform for the formation and study of frictional nanostructured steel, assembly of which is stabilized by fast cooling of the produced chip. Analysis of the mechanical properties has shown extraordinary results at the surface, over 2000 MPa of strength on AISI1045 steel, more than three times the strength of the base material, demonstrating at the same time a reduction of 15% in the elastic modulus. The microscopic analysis suggests a reassembly of the elements in a new lattice of carbon supersaturated nano-ferrite