Skip to main content
Erschienen in: The International Journal of Advanced Manufacturing Technology 3/2020

20.05.2020 | ORIGINAL ARTICLE

Simulation of micro-milling Inconel 718 considering scale effect

verfasst von: Xiaohong Lu, Zhenyuan Jia, Haixing Zhang, Jinhui Qiao, Yixuan Feng, Steven Y. Liang

Erschienen in: The International Journal of Advanced Manufacturing Technology | Ausgabe 3/2020

Einloggen

Aktivieren Sie unsere intelligente Suche, um passende Fachinhalte oder Patente zu finden.

search-config
loading …

Abstract

To study the scale effect during micro-milling process, we establish a modified Johnson-Cook (JC) constitutive model to describe the strengthening behavior of materials on microscale based on the theory of strain gradient plasticity. The VUMAT constitutive subroutine of Inconel 718 is programmed. The radius of the tool edge and its influence on the rake angle are considered. Based on the modified JC constitutive equation, the simulation of micro-milling Inconel 718 process is achieved. The micro-milling Inconel 718 experiments are conducted. The accuracy of the simulation of micro-milling Inconel 718 process considering scale effect is verified by comparing cutting force from experiments with simulation outputs based on the traditional as well as modified JC constitutive equation. It is proved that the simulation outputs of the micro-milling process based on the modified JC constitutive equation are more consistent with the experimental results.

Sie haben noch keine Lizenz? Dann Informieren Sie sich jetzt über unsere Produkte:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

Literatur
1.
Zurück zum Zitat Gao H, Huang Y, Nix WD, Hutchinson JW (1999) Mechanism-based strain gradient plasticity - I. Theory. J Mech Phys Solids 47(6):1239–1263MathSciNetCrossRef Gao H, Huang Y, Nix WD, Hutchinson JW (1999) Mechanism-based strain gradient plasticity - I. Theory. J Mech Phys Solids 47(6):1239–1263MathSciNetCrossRef
2.
Zurück zum Zitat Han CS, Gao H, Huang Y, Nix WD (2005) Mechanism-based strain gradient crystal plasticity - II analysis. J Mech Phys Solids 53(5):1204–1222MathSciNetCrossRef Han CS, Gao H, Huang Y, Nix WD (2005) Mechanism-based strain gradient crystal plasticity - II analysis. J Mech Phys Solids 53(5):1204–1222MathSciNetCrossRef
3.
Zurück zum Zitat Byon SM, Kim HS, Lee Y (2007) Investigation of the size effect on crack propagation using finite element method and strain gradient plasticity. J Mater Process Technol 191(1–3):193–197CrossRef Byon SM, Kim HS, Lee Y (2007) Investigation of the size effect on crack propagation using finite element method and strain gradient plasticity. J Mater Process Technol 191(1–3):193–197CrossRef
4.
Zurück zum Zitat Lee H, Ko S, Han J, Park H, Hwang W (2005) Novel analysis for nanoindentation size effect using strain gradient plasticity. Scr Mater 53(10):1135–1139CrossRef Lee H, Ko S, Han J, Park H, Hwang W (2005) Novel analysis for nanoindentation size effect using strain gradient plasticity. Scr Mater 53(10):1135–1139CrossRef
5.
Zurück zum Zitat Wu J, Liu Z (2010) Modeling of flow stress in orthogonal micro-cutting process based on strain gradient plasticity theory. Int J Adv Manuf Technol 46(1–4):143–149CrossRef Wu J, Liu Z (2010) Modeling of flow stress in orthogonal micro-cutting process based on strain gradient plasticity theory. Int J Adv Manuf Technol 46(1–4):143–149CrossRef
6.
Zurück zum Zitat Lu X, Wang H, Jia Z, Si L, Liang SY (2017) Effects of tool nose corner radius and main cutting-edge radius on cutting temperature in micro-milling Inconel 718 process. In: ASME 2017 12th International Manufacturing Science and Engineering Conference collocated with the JSME/ASME 2017 6th International Conference on Materials and Processing. American Society of Mechanical Engineers Digital Collection Lu X, Wang H, Jia Z, Si L, Liang SY (2017) Effects of tool nose corner radius and main cutting-edge radius on cutting temperature in micro-milling Inconel 718 process. In: ASME 2017 12th International Manufacturing Science and Engineering Conference collocated with the JSME/ASME 2017 6th International Conference on Materials and Processing. American Society of Mechanical Engineers Digital Collection
7.
Zurück zum Zitat Lucca DA, Seo YW, Komanduri R (1993) Effect of tool edge geometry on energy dissipation in ultraprecision machining. CIRP Ann 42(1):83–86CrossRef Lucca DA, Seo YW, Komanduri R (1993) Effect of tool edge geometry on energy dissipation in ultraprecision machining. CIRP Ann 42(1):83–86CrossRef
8.
Zurück zum Zitat Dai X, Zhuang K, Ding H (2019) A systemic investigation of tool edge geometries and cutting parameters on cutting forces in turning of Inconel 718. Int J Adv Manuf Technol 105(1–4):531–543CrossRef Dai X, Zhuang K, Ding H (2019) A systemic investigation of tool edge geometries and cutting parameters on cutting forces in turning of Inconel 718. Int J Adv Manuf Technol 105(1–4):531–543CrossRef
9.
Zurück zum Zitat Zheng M, Xie L, Shang T, Chen X, Fu T (2017) Analysis on the effect of phase boundary in meso-cutting of AISI1045 based on the microstructure-level simulation. Int J Adv Manuf Technol 90(9–12):3229–3238CrossRef Zheng M, Xie L, Shang T, Chen X, Fu T (2017) Analysis on the effect of phase boundary in meso-cutting of AISI1045 based on the microstructure-level simulation. Int J Adv Manuf Technol 90(9–12):3229–3238CrossRef
10.
Zurück zum Zitat Liu K, Melkote SN (2007) Finite element analysis of the influence of tool edge radius on size effect in orthogonal micro-cutting process. Int J Mech Sci 49(5):650–660CrossRef Liu K, Melkote SN (2007) Finite element analysis of the influence of tool edge radius on size effect in orthogonal micro-cutting process. Int J Mech Sci 49(5):650–660CrossRef
11.
Zurück zum Zitat Lai X, Li H, Li C, Lin Z, Ni J (2008) Modelling and analysis of micro scale milling considering size effect, micro cutter edge radius and minimum chip thickness. Int J Mach Tools Manuf 48(1):1–14CrossRef Lai X, Li H, Li C, Lin Z, Ni J (2008) Modelling and analysis of micro scale milling considering size effect, micro cutter edge radius and minimum chip thickness. Int J Mach Tools Manuf 48(1):1–14CrossRef
12.
Zurück zum Zitat Ding H, Shen N, Shin YC (2011) Experimental evaluation and modeling analysis of micromilling of hardened H13 tool steels. J Manuf Sci Eng 133(4) Ding H, Shen N, Shin YC (2011) Experimental evaluation and modeling analysis of micromilling of hardened H13 tool steels. J Manuf Sci Eng 133(4)
13.
Zurück zum Zitat Zhang T, Liu Z, Shi Z, Xu C (2017) Investigation on size effect of specific cutting energy in mechanical micro-cutting. Int J Adv Manuf Technol 91(5–8):2621–2633CrossRef Zhang T, Liu Z, Shi Z, Xu C (2017) Investigation on size effect of specific cutting energy in mechanical micro-cutting. Int J Adv Manuf Technol 91(5–8):2621–2633CrossRef
14.
Zurück zum Zitat Suresh S, Nieh TG, Choi BW (1999) Nano-indentation of copper thin films on silicon substrates. Scr Mater 41(9):951–957CrossRef Suresh S, Nieh TG, Choi BW (1999) Nano-indentation of copper thin films on silicon substrates. Scr Mater 41(9):951–957CrossRef
15.
Zurück zum Zitat Fleck NA, Hutchinson JW (1993) A phenomenological theory for strain gradient effects in plasticity. J Mech Phys Solids 41(12):1825–1857MathSciNetCrossRef Fleck NA, Hutchinson JW (1993) A phenomenological theory for strain gradient effects in plasticity. J Mech Phys Solids 41(12):1825–1857MathSciNetCrossRef
16.
Zurück zum Zitat Taylor GI (1934) The mechanism of plastic deformation of crystals. part I. - theoretical. Proc R Soc London Ser A Contain Pap Math Phys Character 145(855):362–387MATH Taylor GI (1934) The mechanism of plastic deformation of crystals. part I. - theoretical. Proc R Soc London Ser A Contain Pap Math Phys Character 145(855):362–387MATH
17.
Zurück zum Zitat Nye JF (1953) Some geometrical relations in dislocated crystals. Acta Metall 1(2):153–162CrossRef Nye JF (1953) Some geometrical relations in dislocated crystals. Acta Metall 1(2):153–162CrossRef
18.
Zurück zum Zitat Özel T, Zeren E (2004) Determination of work material flow stress and friction for FEA of machining using orthogonal cutting tests. J Mater Process Technol 153:1019–1025CrossRef Özel T, Zeren E (2004) Determination of work material flow stress and friction for FEA of machining using orthogonal cutting tests. J Mater Process Technol 153:1019–1025CrossRef
19.
Zurück zum Zitat Joshi SS, Melkote SN (2004) An explanation for the size-effect in machining using strain gradient plasticity. J Manuf Sci E T ASME 126(4):679–684CrossRef Joshi SS, Melkote SN (2004) An explanation for the size-effect in machining using strain gradient plasticity. J Manuf Sci E T ASME 126(4):679–684CrossRef
20.
Zurück zum Zitat Li GJ (2013) Research on the cutting force modeling during micro-end milling nickel-based superalloy processing. Dissertation for the Degree of Master of Engineering. Dalian University of Technology Li GJ (2013) Research on the cutting force modeling during micro-end milling nickel-based superalloy processing. Dissertation for the Degree of Master of Engineering. Dalian University of Technology
21.
Zurück zum Zitat Kim CJ (2004) Mechanisms of chip formation and cutting dynamics in the micro-scale milling process. Dissertation of the University of Michigan Kim CJ (2004) Mechanisms of chip formation and cutting dynamics in the micro-scale milling process. Dissertation of the University of Michigan
22.
Zurück zum Zitat Vogler MP, Kapoor SG, DeVor RE (2004) On the modeling and analysis of machining performance in micro-endmilling, part II: cutting force prediction. J Manuf Sci E T ASME 126(4):695–705CrossRef Vogler MP, Kapoor SG, DeVor RE (2004) On the modeling and analysis of machining performance in micro-endmilling, part II: cutting force prediction. J Manuf Sci E T ASME 126(4):695–705CrossRef
23.
Zurück zum Zitat Lee HU, Cho DW, Ehmann KF (2008) A mechanistic model of cutting forces in micro-end-milling with cutting-condition-independent cutting force coefficients. J Manuf Sci Eng 130(3) Lee HU, Cho DW, Ehmann KF (2008) A mechanistic model of cutting forces in micro-end-milling with cutting-condition-independent cutting force coefficients. J Manuf Sci Eng 130(3)
24.
Zurück zum Zitat Kobayashi T, Simons JW, Brown CS, Shockey DA (2008) Plastic flow behavior of Inconel 718 under dynamic shear loads. Int J Impact Eng 35(5):389–396CrossRef Kobayashi T, Simons JW, Brown CS, Shockey DA (2008) Plastic flow behavior of Inconel 718 under dynamic shear loads. Int J Impact Eng 35(5):389–396CrossRef
25.
Zurück zum Zitat Ding H, Shen N, Shin YC (2012) Thermal and mechanical modeling analysis of laser-assisted micro-milling of difficult-to-machine alloys. J Mater Process Technol 212(3):601–613CrossRef Ding H, Shen N, Shin YC (2012) Thermal and mechanical modeling analysis of laser-assisted micro-milling of difficult-to-machine alloys. J Mater Process Technol 212(3):601–613CrossRef
26.
Zurück zum Zitat Zhu DR (2007) Study on the roughness and residual stress of micro-milled surface. Dissertation for the Degree of Master of Engineering. Harbin Institute of Technology Zhu DR (2007) Study on the roughness and residual stress of micro-milled surface. Dissertation for the Degree of Master of Engineering. Harbin Institute of Technology
27.
Zurück zum Zitat Sharman A, Dewes RC, Aspinwall DK (2001) Tool life when high speed ball nose end milling Inconel 718™. J Mater Process Technol 118(1–3):29–35CrossRef Sharman A, Dewes RC, Aspinwall DK (2001) Tool life when high speed ball nose end milling Inconel 718™. J Mater Process Technol 118(1–3):29–35CrossRef
28.
Zurück zum Zitat Shi C (2012) Constitutive modeling of materials and simulation of size effect in micro-cutting process. Dissertation for the Degree of Master of Engineering. Huazhong University of Science & Technology Shi C (2012) Constitutive modeling of materials and simulation of size effect in micro-cutting process. Dissertation for the Degree of Master of Engineering. Huazhong University of Science & Technology
Metadaten
Titel
Simulation of micro-milling Inconel 718 considering scale effect
verfasst von
Xiaohong Lu
Zhenyuan Jia
Haixing Zhang
Jinhui Qiao
Yixuan Feng
Steven Y. Liang
Publikationsdatum
20.05.2020
Verlag
Springer London
Erschienen in
The International Journal of Advanced Manufacturing Technology / Ausgabe 3/2020
Print ISSN: 0268-3768
Elektronische ISSN: 1433-3015
DOI
https://doi.org/10.1007/s00170-020-05426-3

Weitere Artikel der Ausgabe 3/2020

The International Journal of Advanced Manufacturing Technology 3/2020 Zur Ausgabe

    Marktübersichten

    Die im Laufe eines Jahres in der „adhäsion“ veröffentlichten Marktübersichten helfen Anwendern verschiedenster Branchen, sich einen gezielten Überblick über Lieferantenangebote zu verschaffen.