Modeling Grain Size Evolution under Thermomechanical Loads during Machining Using a Meshless Approach

Procedia CIRP, vol. 144, pp. 381–386

Abstract

During machining, the workpiece surface experiences intense thermomechanical loads, leading to changes in its crystalline structure and stress state. These subsurface and grain size modifications critically influence the mechanical properties of the finished component. Grain size evolution is typically investigated through cutting experiments or FEM-based chip formation simulations. However, both approaches are costly and time-consuming, limiting their broader applicability. This work presents a meshless simulation approach as an efficient alternative to FEM, incorporating a physically based grain size evolution model that accounts for strain, strain rate, and temperature effects such as dynamic recrystallization. The method leverages GPU parallelization to significantly reduce computation time. Model validation is performed through orthogonal cutting experiments and microstructure measurements. By integrating experimental data with simulation, the study systematically analyzes the influence of cutting parameters on thermomechanical loading and the resulting grain size modification. The proposed framework enables rapid and reliable prediction of subsurface grain structure evolution, providing a valuable tool for optimizing machining processes, tool designs, and surface integrity in both industrial and research contexts.

Authors 5

1. Hui Liu corresponding Aachen Manufacturing Technology Institute (MTI)

   RWTH Aachen University

   Affiliation as printed

   Manufacturing Technology Institute (MTI) at RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, Germany

2. Pedro Henrique de Carvalho
3. Anna Kibireva Aachen Manufacturing Technology Institute (MTI)

   RWTH Aachen University

   Affiliation as printed

   Manufacturing Technology Institute (MTI) at RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, Germany

4. Markus Meurer Aachen Manufacturing Technology Institute (MTI)

   RWTH Aachen University

   Affiliation as printed

   Manufacturing Technology Institute (MTI) at RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, Germany

5. Thomas Bergs Aachen Fraunhofer Institute for Production Technology IPT Manufacturing Technology Institute (MTI)

   Fraunhofer Institute for Production Technology IPT · RWTH Aachen University

   Affiliation as printed

   Fraunhofer Institute for Production Technology IPT, Steinbachstr. 17, 52074 Aachen, Germany

   Manufacturing Technology Institute (MTI) at RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, Germany