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Technical Brief

Subsurface deformation generated by orthogonal cutting: analytical modelling and experimental verification

[+] Author and Article Information
Dong Zhang

State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, China
zhangdong@hust.edu.cn

Xiao-Ming Zhang

State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, China
zhangxm.duyi@gmail.com

Leopold Juergen

Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz 09661, Germany
jleopold@tbz-pariv.de

Han Ding

State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, China
famt@hust.edu.cn

1Corresponding author.

ASME doi:10.1115/1.4036994 History: Received January 19, 2017; Revised May 31, 2017

Abstract

Subsurface deformation during a cutting process has attracted a great deal of attention due to its tightly relationship with subsurface hardening, microstructure alteration, grain refinement and white layer formation. To predict the subsurface deformation of the machined components, an analytical model is proposed in this paper. The mechanical and thermal loads exerted on the primary and tertiary shear zones are predicted by a combination of Oxley’s predictive model and Fang’s slip line field. The stress field and temperature field are calculated based on contact mechanics and the moving heat sources theory, respectively. However, the elastic-plastic regime induced by the material yielding hinders the direct derivation of subsurface plastic deformation from the stress field and the work material constitutive model. To tackle this problem, a blending function of the increment of elastic strain is developed to derive the plastic strain. In addition, a sophisticated material constitutive model considering strain hardening, strain rate sensitivity, and thermal softening effects of work material is incorporated into this analytical model. To validate this model, finite element simulations of the subsurface deformation during orthogonal cutting of AISI 52100 steel are conducted. Experimental verification of the subsurface deformation is carried out through a novel subsurface deformation measurement approach based on digital image correlation technique. To demonstrate applications of the subsurface deformation prediction, the subsurface micro hardness of the machined component is experimentally tested and compared against the predicted values based on the proposed method.

Copyright (c) 2017 by ASME
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