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Technical Brief

Physics-Based Microstructure Simulation for Drilled Hole Surface in Hardened Steel

[+] Author and Article Information
Ninggang Shen

Department of Mechanical and Industrial Engineering,
The University of Iowa,
2312 Seamans Center,
Iowa City, IA 52242

Hongtao Ding

Department of Mechanical and Industrial Engineering,
The University of Iowa,
2410 Seamans Center,
Iowa City, IA 52242
e-mail: hongtao-ding@uiowa.edu

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received June 11, 2013; final manuscript received May 17, 2014; published online June 5, 2014. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 136(4), 044504 (Jun 05, 2014) (5 pages) Paper No: MANU-13-1255; doi: 10.1115/1.4027732 History: Received June 11, 2013; Revised May 17, 2014

For a fully hardened steel material, hole surface microstructures are often subject to microstructural transition because of the intense thermomechanical loading. A white layer can be formed on the surface of a drilled hole of hardened carbon steels, which results from two mechanisms: thermally driven phase transformation and mechanical grain refinement due to severe plastic deformation. In this study, a multistep numerical analysis is conducted to investigate the potential mechanism of surface microstructure alterations in hard drilling. First, three-dimensional (3D) finite element (FE) simulations are performed using a relative coarse mesh with advantedge for hard drilling of AISI 1060 steel to achieve the steady-state solution for thermal and deformation fields. Defining the initial condition of the cutting zone using the 3D simulation results, a multiphysics model is then implemented in two-dimensional (2D) coupled Eulerian–Lagrangian (CEL) FE analysis in abaqus to model both phase transformation and grain refinement at a fine mesh to comprehend the surface microstructure alteration. Experimental results are used to demonstrate the capability of this multiphysics model to predict critical surface microstructural attributes.

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Figures

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Fig. 1

Multistep numerical models for hard drilling

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Fig. 2

Simulation results for test-1: (a) temperature; (b) equivalent plastic strain; (c) total dislocation density; and (d) grain size

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Fig. 3

Simulation results and experimental data for test-1. (a) Simulated profiles of shear strain, total dislocation density, grain size along the penetration; (b) SEM micrograph; and (c) TEM micrograph near hole surface [5].

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Fig. 4

Simulation of phase composition and microhardness near the hole surface for test-1

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Fig. 5

Effects of drilling parameters: (a) cutting speed and (b) feed

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