Cutting force based surface integrity soft-sensor when hard machining AISI 4140

tm - Technisches Messen, vol. 87, pp. 683–693

Abstract

Abstract Workpiece rim zone modifications during hard machining can be explained with the high thermo-mechanical loads induced by the cutting process. The formation of White Layers with a fine-grained microstructure by dynamic recrystallization (DRX) is one of those surface modifications that can negatively affect the functionality of a machined part by changing the residual stress state and facilitating crack initiation. As a consequence, the fatigue life of the machined parts is reduced. It is therefore of great interest to understand the thermo-mechanical conditions which induce White Layers formation in order to be able to control them by in-situ measurements if necessary. For this purpose, a cutting force based Soft-Sensor is developed in this study which enables the in-process estimation of White Layer thickness. Therefore, a cutting force based analytical model is used to estimate the resulting temperature fields and correlated with validated numerical chip formation simulations. In addition, the predictions of the White Layer thickness of the analytical model are then compared using light microscopy and the results of the numerical finite element model, in which a DRX model is additionally implemented.

Authors 7

1. Markus Meurer Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   9165 RWTH Aachen University , Laboratory for Machine Tools and Production Engineering (WZL) , Aachen , Germany

2. Berk Tekkaya corresponding Aachen Steel Institute

   RWTH Aachen University

   Affiliation as printed

   9165 RWTH Aachen University , Integrity of Materials and Structures, Steel Institute (IEHK) , Aachen , Germany

3. Thorsten Augspurger Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   9165 RWTH Aachen University , Laboratory for Machine Tools and Production Engineering (WZL) , Aachen , Germany

4. Thomas Pullen Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   9165 RWTH Aachen University , Laboratory for Machine Tools and Production Engineering (WZL) , Aachen , Germany

5. Daniel Schraknepper Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   9165 RWTH Aachen University , Laboratory for Machine Tools and Production Engineering (WZL) , Aachen , Germany

6. Thomas Bergs Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   9165 RWTH Aachen University , Laboratory for Machine Tools and Production Engineering (WZL) , Aachen , Germany

7. Sebastian Münstermann Aachen Steel Institute

   RWTH Aachen University

   Affiliation as printed

   9165 RWTH Aachen University , Integrity of Materials and Structures, Steel Institute (IEHK) , Aachen , Germany