Finite Element Modeling of Microstructural Changes in Turning of AA7075-T651 Alloy and Validation

The surface characteristics of a machined product strongly influence its functional performance. During machining, the grain size of the surface is frequently modified, thus the properties of the machined surface are different to that of the original bulk material. These changes must be taken into account when modeling the surface integrity effects resulting from machining. In the present work, grain size changes induced during turning of AA 7075-T651 (160 HV) alloy are modeled using the Finite Element (FE) method and a user subroutine is implemented in the FE code to describe the microstructural change and to simulate the dynamic recrystallization, with the consequent formation of new grains. In particular, a procedure utilizing the Zener-Hollomon and Hall-Petch equations is implemented in the user subroutine to predict the evolution of the material grain size and the surface hardness when varying the cutting speeds (180 - 720 m/min) and tool nose radii (0.4 - 1.2 mm). All simulations were performed for dry cutting conditions using uncoated carbide tools. The effectiveness of the proposed FE model was demonstrated through its capability to predict grain size evolution and hardness modification from the bulk material to machined surface. The model is validated by comparing the predicted results with those experimentally observed

Evaluating Future Nanotechnology: The Net Societal Impacts of Atomically Precise Manufacturing

Atomically precise manufacturing (APM) is the assembly of materials with atomic precision. APM does not currently exist, and may not be feasible, but if it is feasible, then the societal impacts could be dramatic. This paper assesses the net societal impacts of APM across the full range of important APM sectors: general material wealth, environmental issues, military affairs, surveillance, artificial intelligence, and space travel. Positive effects were found for material wealth, the environment, military affairs (specifically nuclear disarmament), and space travel. Negative effects were found for military affairs (specifically rogue actor violence and AI. The net effect for surveillance was ambiguous. The effects for the environment, military affairs, and AI appear to be the largest, with the environment perhaps being the largest of these, suggesting that APM would be net beneficial to society. However, these factors are not well quantified and no definitive conclusion can be made. One conclusion that can be reached is that if APM R&D is pursued, it should go hand-in-hand with effective governance strategies to increase the benefits and reduce the harms

Finite element simulation of semi-finishing turning of Electron Beam Melted Ti6Al4V under dry and cryogenic cooling

open6noIn the last few years, important step forwards have been made on Finite Element Simulation of machining operations. Wrought Ti6Al4V alloy has been deeply investigated both numerically and experimentally due to its wide application in the industry. Recently, Additive Manufacturing technologies as the Electron Beam Melting and the Direct Melting Laser Sintering are more and more employed in the production of biomedical and aeronautical components made of Ti6Al4V alloy. Fine acicular microstructures are generated by the application of additive manufacturing technologies, affecting the mechanical properties and the machinability. By the consequence, this peculiarity has to be considered in modelling the material behaviour. In this work, a numerical analysis of cylindrical external turning on Electron Beam Melted (EBM) Ti6Al4V alloy is presented. A Johnson-Cook constitutive equation was implemented as a flow stress model and adapted with respect to the wrought Ti6Al4V alloy. The model was calibrated and validated through the cutting forces and temperatures measurements acquired under dry and cryogenic lubricating conditions.openBordin, A; Imbrogno, S.; Rotella, G.; Bruschi, S.; Ghiotti, A.; Umbrello, D.Bordin, Alberto; Imbrogno, S.; Rotella, G.; Bruschi, Stefania; Ghiotti, Andrea; Umbrello, D

Numerical Simulation of Machining Nickel-Based Alloy

none3The phenomenological models for material flow stress and fracture, typically used in the Finite Element simulations of machining Nickel-based alloys, are often deemed to represent only certain metallurgical material states. In contrast, these models are not suitable to describe the constitutive behavior of the workpiece for different metallurgical states (i.e., annealed, aged, etc.) and, consequently, different hardness values. Since the description of the material behavior requires correct formulation of the constitutive law, new flow stress models which include also the hardness effect should be developed and used, for computer simulation of machining Nickel-based alloys. This paper describes the development of a hardness-based flow stress and fracture models for machining Inconel 718 alloy which can be applied for a wide range of work material hardness. These models have been implemented in a non-isothermal viscoplastic numerical model to simulate the influence of work material hardness on the chip formation process. The predicted results are being validated with experimental results properly carried out for this research. They are found to satisfactory predict the cutting forces, the temperature and the chip morphology from continuous to segmented chip as the hardness values changeopenDel Prete A.; Filice L.; Umbrello D.;DEL PRETE, Antonio; Filice, L.; Umbrello, D

Finite Element Simulation of Residual Stresses in Cryogenic Machining of AZ31B Mg Alloy

AbstractMagnesium alloys are lightweight materials primarily used in transportation industry, and are also emerging as a potential material for biodegradable fixation implants. However, unsatisfactory corrosion resistance largely limits the application of these materials. Residual stresses were reported to have significant influence on corrosion resistance of Mg alloys. In this study, a finite element model was developed to simulate the residual stresses in cryogenic machining of AZ31B Mg alloy. After calibration using experimental data, numerical simulations were conducted to study the influence of cutting edge radius and cooling method (dry vs. cryogenic) on residual stresses. The model can be used to establish proper cutting conditions to induce compressive residual stresses to enhance the corrosion resistance of Mg alloys

Innovative manufacturing process of functionalized PA2200 for reduced adhesion properties

This work proposes an approach to fabricate micro patterned surfaces on PA2200 polyamide in order to improve its performance in terms of wettability and adhesion. In more detail, the present work aims to change the wettability of the surface and decrease their bacteria adhesion tendency. The experimental procedure consists of imprinting a set of different micro patterned structures over the polymer in order to verify the effectiveness of the methodology to change the contact angle of the surface, and in turn, reduce the occurrence of bacteria adhesion. Four different surface patterning were produced by laser ablation of a commercially pure titanium alloy, and then imprinted over the polyamide by surface stamping. The resulting surfaces were analyzed by topographical characterization and scanning electron microscopy. The wettability was probed by contact angle measurements while the bacteria adhesion was analyzed by adhesion test. The experimental results demonstrate the effectiveness of the method to modify the surface characteristics and to obtain a reliable patterned surface without using chemical hazardous material; opening to the possibility to replicate more complex structures and to obtain graded engineering surfaces

Finite element modeling of microstructural changes in hard machining of SAE 8620

Surface and subsurface microstructural characterization after machining operations is a topic of great interest for both academic and industrial research activities. This paper presents a newly developed finite element (FE) model able to describe microstructural evolution and dynamic recrystallization (DRX) during orthogonal hard machining of SAE 8620 steel. In particular, it predicts grain size and hardness variation by implementing a user subroutine involving a hardness-based flow stress and empirical models. The model is validated by comparing its output with the experimental results available in literature at varying the cutting speed, inser0000-0001-6268-6720t geometry and flank wear. The results show a good ability of the customized model to predict the thermo-mechanical and microstructural phenomena taking place during the selected processes

An Experimental Investigation of Residual Stresses in Hard Machining of AISI 52100 Steel

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Experimental Comparison of the MIG and Friction Stir Welding Processes for AA 6005 Aluminium Alloy

In this study, the mechanical properties of welded joints of AA 6005 aluminum alloy obtained with friction stir welding (FSW) and conventional metal inert gas welding (MIG) are studied. FSW welds were carried out on a semi-automatic milling machine. The performance of FSW and MIG welded joints were identified using tensile and bending impact tests, as far as the environmental aspects are also included in the discussion. The joints obtained with FSW and MIG processes were also investigated in their microstructure. The results indicate that, the microstructure of the friction stir weld is different from that of MIG welded joint. The weld nugget consists of small grains in FSW than those found in MIG weld. Taking into consideration the process conditions and requirements, FSW and MIG processes were also compared with each other to understand the advantages and disadvantages of the processes for welding applications of studied Al alloy. Better tensile and bending strength were obtained with FSW welded joints

Finite Element Modeling of Microstructural Changes in Turning of AA7075-T651 Alloy and Validation

The surface characteristics of a machined product strongly influence its functional performance. During machining, the grain size of the surface is frequently modified, thus the properties of the machined surface are different to that of the original bulk material. These changes must be taken into account when modeling the surface integrity effects resulting from machining. In the present work, grain size changes induced during turning of AA 7075-T651 (160 HV) alloy are modeled using the Finite Element (FE) method and a user subroutine is implemented in the FE code to describe the microstructural change and to simulate the dynamic recrystallization, with the consequent formation of new grains. In particular, a procedure utilizing the Zener-Hollomon and Hall-Petch equations is implemented in the user subroutine to predict the evolution of the material grain size and the surface hardness when varying the cutting speeds (180 - 720 m/min) and tool nose radii (0.4 - 1.2 mm). All simulations were performed for dry cutting conditions using uncoated carbide tools. The effectiveness of the proposed FE model was demonstrated through its capability to predict grain size evolution and hardness modification from the bulk material to machined surface. The model is validated by comparing the predicted results with those experimentally observed