Finite Element Analysis of Plastic Deformation in Ultrasonic Vibration Superimposed Face Milling of Steel X46Cr13

Finite Element Analysis of Plastic Deformation in Ultrasonic Vibration Superimposed Face Milling of Steel X46Cr13

Ultrasonic vibration superimposed face milling enables the generation of predefined surface microstructures by an appropriate setting of the process parameters. The geometrical reproducibility of the surface characteristics depends strongly on the plastic material deformation. Thus, the precise pred...

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Bibliographic Details
Published in:Micromachines (Basel) Vol. 15; no. 6; p. 730
Main Authors: Börner, Richard, Steinert, Philipp, Bandaru, Nithin Kumar, Schubert, Andreas
Format: Journal Article
Language:English
Published: Switzerland MDPI AG 30-05-2024
MDPI
Subjects:
Abaqus
Aluminum
Comparative analysis
Cutting tools
Deformation
Deformation effects
Elastic deformation
Face milling
Finite element method
Kinematics
Martensitic stainless steels
Microstructure
Microstructured surfaces
Numerical models
numerical simulation
Plastic deformation
Process parameters
Simulation
Simulation models
Surface properties
Titanium alloys
Ultrasonic vibration
ultrasonic vibration superimposed machining
Vibration
Vibration analysis
X46Cr13
Abaqus
X46Cr13
microstructure
ultrasonic vibration superimposed machining
numerical simulation
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Summary:Ultrasonic vibration superimposed face milling enables the generation of predefined surface microstructures by an appropriate setting of the process parameters. The geometrical reproducibility of the surface characteristics depends strongly on the plastic material deformation. Thus, the precise prediction of the emerging surface microstructures using kinematic simulation models is limited, because they ignore the influence of material flow. Consequently, the effects of plastic as well as elastic deformation are investigated in depth by finite element analysis. Microstructured surfaces resulting from these numerical models are characterized quantitatively by areal surface parameters and compared to those from a kinematical simulation and a real machined surface. A high degree of conformity between the values of the simulated surfaces and the measured values is achieved, particularly with regard to material distribution. Deficits in predictability exist primarily due to deviations in plastic deformation. Future research can address this, either by implementing a temperature consideration or adapting specific modeling aspects like an adjusted depth of cut or experimental validated material parameters.
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ISSN:2072-666X
2072-666X
DOI:10.3390/mi15060730